Layered barrier cans for pumps and methods of producing the same

ABSTRACT

Layered barrier cans and methods of producing the same are disclosed herein. An example shroud disclosed herein includes an inner shell including a first non-metallic material, an outer shell including the first non-metallic material or a second non-metallic material, and a metal core shell positioned between the inner shell and the outer shell.

RELATED APPLICATION

This patent claims the benefit of Indian Provisional Patent ApplicationNo. 202211025722, which was filed on May 3, 2022. Indian ProvisionalPatent Application No. 202211025722 is hereby incorporated herein byreference in its entirety. Priority to Indian Provisional PatentApplication No. 202211025722 is hereby claimed.

FIELD OF THE DISCLOSURE

This disclosure relates generally to fluid pumps, and, moreparticularly, to layered barrier cans for pumps and methods of producingthe same.

BACKGROUND

Aircraft typically include various accessory systems supporting theoperation of the aircraft and/or its gas turbine engine(s). For example,such accessory systems may include a lubrication system that lubricatescomponents of the engine(s), an engine cooling system that providescooling air to engine components, an environmental control system thatprovides cooled air to the cabin of the aircraft, and/or the like. Assuch, heat is added or removed from a fluid (e.g., oil, air, etc.)during operation of these accessory systems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an example aircraft.

FIG. 2 is a schematic cross-sectional view of an example gas turbineengine of an aircraft.

FIG. 3 is a schematic diagram of an example thermal management systemfor transferring heat between fluids.

FIG. 4 illustrates an example thermal transport bus pump.

FIG. 5 illustrates a first example radially coupled fluid pump system inaccordance with the teachings disclosed herein.

FIG. 6 illustrates a second example radially coupled fluid pump systemin accordance with the teachings disclosed herein.

FIG. 7 illustrates a third example radially coupled fluid pump system inaccordance with the teachings disclosed herein.

FIG. 8 is a flow diagram illustrating an operation of the radiallycoupled fluid pump system.

FIG. 9 illustrates example integrated bearing systems for dynamicallysupporting a rotating shaft in an example pump system in accordance withthe teachings of this disclosure.

FIG. 10 illustrates an example integrated bearing system for dynamicallysupporting the rotating shaft in the example pump system in accordancewith the teachings of this disclosure.

FIG. 11 illustrates an example sprag clutch for engaging and disengagingbearings in the example integrated bearing system in accordance with theteachings of this disclosure.

FIG. 12A illustrates an example engaged state of an example spragelement of the example integrated bearing system in accordance with theteachings of this disclosure.

FIG. 12B illustrates an example disengaged state of the example spragelement of the example integrated bearing system in accordance with theteachings of this disclosure.

FIG. 13 illustrates example load paths that the example integratedbearing systems support during operation of the example pump system inaccordance with the teachings of this disclosure.

FIG. 14 is a flow diagram illustrating an example operation of theexample integrated bearing systems of the example pump system.

FIG. 15 illustrates a first example barrier can in accordance with theteachings disclosed herein.

FIG. 16 illustrates an example inner shell that can be utilized in thefirst example barrier can of FIG. 15 .

FIG. 17A illustrates a cross-section of the first example barrier canafter a first example manufacturing operation.

FIG. 17B illustrates a cross-section of the first example barrier canafter a second example manufacturing operation.

FIG. 17C illustrates a cross-section of the first example barrier canafter a third example manufacturing operation.

FIG. 18 is a flowchart representative of an example method tomanufacture the first example barrier can of FIGS. 15 and 17A-C.

FIG. 19 illustrates a second example barrier can in accordance with theteachings disclosed herein.

FIG. 20A illustrates first example fibers of the second example barriercan of FIG. 19 .

FIG. 20B illustrates second example fibers of the second example barriercan of FIG. 19 .

FIG. 20C illustrates third example fibers of the second example barriercan of FIG. 19 .

FIG. 20D illustrates fourth example fibers of the second example barriercan of FIG. 19 .

FIG. 21 illustrates a magnified view of a portion of the second examplebarrier can of FIG. 19 .

FIG. 22A is a flowchart representative of an example method tomanufacture the second example barrier can of FIGS. 19, 20A-D, and 21.

FIG. 22B is a flowchart representative of another example method tomanufacture the second example barrier can of FIGS. 19, 20A-D, and 21.

FIG. 23 illustrates an example pump system including a first example oilseparator in accordance with the teachings disclosed herein.

FIG. 24 illustrates another example pump system including a secondexample oil separator in accordance with the teachings disclosed herein.

FIG. 25 illustrates another example pump system including the secondexample oil separator and a third example oil separator in accordancewith the teachings disclosed herein.

FIG. 26 illustrates another example pump system including a planetarygearbox in accordance with the teachings disclosed herein.

FIG. 27 illustrates a cross-section of the planetary gearbox of FIG. 26.

FIG. 28 illustrates another example pump system including bearingassemblies in accordance with the teachings disclosed herein.

FIG. 29 is a schematic representation of support provided by the bearingassemblies of FIG. 28 .

FIG. 30A illustrates a first example rotary separator that can beutilized in the pump systems of FIGS. 23-26 and 28 .

FIG. 30B illustrates a second example rotary separator that can beutilized in the pump systems of FIGS. 23-26 and 28 .

FIG. 30C illustrates a third example rotary separator that can beutilized in the pump systems of FIGS. 23-26 and 28 .

FIG. 31A illustrates a first example stationary separator that can beutilized in the pump systems of FIGS. 23-26 and 28 .

FIG. 31B illustrates another example orientation of the first examplestationary separator of FIG. 31A.

FIG. 31C illustrates a second example stationary separator that can beutilized in the pump systems of FIGS. 23-26 and 28 .

FIG. 32 is a schematic representation of a first example layout that canbe associated with the pump systems of FIGS. 23-26 and 28 .

FIG. 33 is a schematic representation of a second example layout thatcan be associated with the pump systems of FIGS. 23-26 and 28 .

FIG. 34 is a schematic representation of a third example layout that canbe associated with the pump systems of FIGS. 23-26 and 28 .

FIG. 35 is a schematic representation of a fourth example layout thatcan be associated with the pump systems of FIGS. 23-26 and 28 .

FIG. 36 illustrates a first example axial flux motor driven pump systemfor pressurizing fluid in closed loop systems in accordance with theteachings of this disclosure.

FIG. 37 illustrates a second example axial flux motor driven pump systemfor pressurizing fluid in closed loop systems in accordance with theteachings of this disclosure.

The figures are not to scale. In general, the same reference numberswill be used throughout the drawing(s) and accompanying writtendescription to refer to the same or like parts.

DETAILED DESCRIPTION

“Including” and “comprising” (and all forms and tenses thereof) are usedherein to be open ended terms. Thus, whenever a claim employs any formof “include” or “comprise” (e.g., comprises, includes, comprising,including, having, etc.) as a preamble or within a claim recitation ofany kind, it is to be understood that additional elements, terms, etc.,may be present without falling outside the scope of the correspondingclaim or recitation. As used herein, when the phrase “at least” is usedas the transition term in, for example, a preamble of a claim, it isopen-ended in the same manner as the term “comprising” and “including”are open ended. The term “and/or” when used, for example, in a form suchas A, B, and/or C refers to any combination or subset of A, B, C such as(1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) Bwith C, or (7) A with B and with C. As used herein in the context ofdescribing structures, components, items, objects and/or things, thephrase “at least one of A and B” is intended to refer to implementationsincluding any of (1) at least one A, (2) at least one B, or (3) at leastone A and at least one B. Similarly, as used herein in the context ofdescribing structures, components, items, objects and/or things, thephrase “at least one of A or B” is intended to refer to implementationsincluding any of (1) at least one A, (2) at least one B, or (3) at leastone A and at least one B. As used herein in the context of describingthe performance or execution of processes, instructions, actions,activities and/or steps, the phrase “at least one of A and B” isintended to refer to implementations including any of (1) at least oneA, (2) at least one B, or (3) at least one A and at least one B.Similarly, as used herein in the context of describing the performanceor execution of processes, instructions, actions, activities and/orsteps, the phrase “at least one of A or B” is intended to refer toimplementations including any of (1) at least one A, (2) at least one B,or (3) at least one A and at least one B.

As used herein, singular references (e.g., “a”, “an”, “first”, “second”,etc.) do not exclude a plurality. The term “a” or “an” object, as usedherein, refers to one or more of that object. The terms “a” (or “an”),“one or more”, and “at least one” are used interchangeably herein.Furthermore, although individually listed, a plurality of means,elements or method actions may be implemented by, e.g., the same entityor object. Additionally, although individual features may be included indifferent examples or claims, these may possibly be combined, and theinclusion in different examples or claims does not imply that acombination of features is not feasible and/or advantageous.

As used herein, unless otherwise stated, the term “above” describes therelationship of two parts relative to Earth. A first part is above asecond part if the second part has at least one part between Earth andthe first part. Likewise, as used herein, a first part is “below” asecond part when the first part is closer to the Earth than the secondpart. As noted above, a first part can be above or below a second partwith one or more of: other parts therebetween, without other partstherebetween, with the first and second parts touching, or without thefirst and second parts being in direct contact with one another.

As used in this application, stating that any part (e.g., a layer, film,area, region, or plate) is in any way on (e.g., positioned on, locatedon, disposed on, or formed on, etc.) another part, indicates that thereferenced part is either in contact with the other part, or that thereferenced part is above the other part with one or more intermediatepart(s) located therebetween.

As used herein, connection references (e.g., attached, coupled,connected, and joined) may include intermediate members between theelements referenced by the connection reference and/or relative movementbetween those elements unless otherwise indicated. As such, connectionreferences do not necessarily infer that two elements are directlyconnected and/or in fixed relation to each other. As used herein,stating that any part is in “contact” with another part is defined tomean that there is no intermediate part between the two parts.

Unless specifically stated otherwise, descriptors such as “first,”“second,” “third,” etc., are used herein without imputing or otherwiseindicating any meaning of priority, physical order, arrangement in alist, and/or ordering in any way, but are merely used as labels and/orarbitrary names to distinguish elements for ease of understanding thedisclosed examples. In some examples, the descriptor “first” may be usedto refer to an element in the detailed description, while the sameelement may be referred to in a claim with a different descriptor suchas “second” or “third.” In such instances, it should be understood thatsuch descriptors are used merely for identifying those elementsdistinctly that might, for example, otherwise share a same name.

Approximating language, as used herein throughout the specification andclaims, is applied to modify any quantitative representation that couldpermissibly vary without resulting in a change in the basic function towhich it is related. Accordingly, a value modified by a term or terms,such as “about”, “approximately”, and “substantially”, are not to belimited to the precise value specified. In at least some instances, theapproximating language may correspond to the precision of an instrumentfor measuring the value, or the precision of the methods or machines forconstructing or manufacturing the components and/or systems. Forexample, the approximating language may refer to being within a tenpercent margin.

The terms “forward” and “aft” refer to relative positions within a gasturbine engine, pump, or vehicle, and refer to the normal operationalattitude of the gas turbine engine, pump, or vehicle. For example, withregard to a gas turbine engine, forward refers to a position closer toan engine inlet and aft refers to a position closer to an engine nozzleor exhaust. Further, with regard to a pump, forward refers to a positioncloser to a pump inlet and aft refers to a position closer to an end ofthe pump opposite the inlet.

The terms “upstream” and “downstream” refer to the relative directionwith respect to a flow in a pathway. For example, with respect to afluid flow, “upstream” refers to the direction from which the fluidflows, and “downstream” refers to the direction to which the fluidflows.

As used herein, the phrase “in communication,” including variationsthereof, encompasses direct communication and/or indirect communicationthrough one or more intermediary components, and does not require directphysical (e.g., wired) communication and/or constant communication, butrather additionally includes selective communication at periodicintervals, scheduled intervals, aperiodic intervals, and/or one-timeevents.

As used herein, “processor circuitry” is defined to include (i) one ormore special purpose electrical circuits structured to perform specificoperation(s) and including one or more semiconductor-based logic devices(e.g., electrical hardware implemented by one or more transistors),and/or (ii) one or more general purpose semiconductor-based electricalcircuits programmed with instructions to perform specific operations andincluding one or more semiconductor-based logic devices (e.g.,electrical hardware implemented by one or more transistors). Examples ofprocessor circuitry include programmed microprocessors, FieldProgrammable Gate Arrays (FPGAs) that may instantiate instructions,Central Processor Units (CPUs), Graphics Processor Units (GPUs), DigitalSignal Processors (DSPs), XPUs, or microcontrollers and integratedcircuits such as Application Specific Integrated Circuits (ASICs). Forexample, an XPU may be implemented by a heterogeneous computing systemincluding multiple types of processor circuitry (e.g., one or moreFPGAs, one or more CPUs, one or more GPUs, one or more DSPs, etc.,and/or a combination thereof) and application programming interface(s)(API(s)) that may assign computing task(s) to whichever one(s) of themultiple types of the processing circuitry is/are best suited to executethe computing task(s).

As used herein, in the context of describing the position and/ororientation of a first object relative to a second object, the term“substantially orthogonal” encompasses the term orthogonal and morebroadly encompasses a meaning whereby the first object is positionedand/or oriented relative to the second object at an absolute angle of nomore than five degrees (5°) from orthogonal. For example, a first axisthat is substantially orthogonal to a second axis is positioned and/ororiented relative to the second axis at an absolute angle of no morethan five degrees (5°) from orthogonal.

As used herein, “radially” is used to express a point or points along aradial vector originating at a central axis of a rotating body andpointing perpendicularly outward from the central axis. In someexamples, two gears are said to be radially connected or coupled,meaning that the two gears are in physical contact with each other atpoint(s) along the circumferential outer edge surface of the gears viainterlocking gear teeth. In some examples, two pulleys are said to beradially connected or coupled, meaning that the two pulleys are inphysical contact with a drive belt at point(s) along the circumferentialouter edge surface of the pulleys.

Centrifugal fluid pumps move fluid through systems by convertingrotational kinetic energy of an impeller to hydrodynamic energy of aflowing fluid. In other words, the angular velocity of the impeller isdirectly proportional to the flow rate of the flowing fluid exiting thepump. The impeller is provided a change in rotational kinetic energyfrom an electric motor applying mechanical work to an impeller shaftcoupled to the impeller and to the rotor of the electric motor. Therotor is provided a change in mechanical work over a period of time(i.e., mechanical power) from a stator in the electric motor applyingelectromagnetic forces to the rotor in the form of torque. If the motorsupplies a constant amount of electrical energy to the stator, then therotor will supply a constant amount of mechanical energy to theimpeller. In this case, the mechanical power supplied to the pump by theelectric motor would be equal to the quotient of the rotational kineticenergy and the amount of time the power is being supplied. In rotationalsystems, such as a centrifugal fluid pump, the mechanical power of theimpeller is equal to the product of the torque and the angular velocity.If the rotor of the electric motor and the impeller shaft of thecentrifugal fluid pump are coupled axially (e.g., by a magneticcoupling), then the torque and angular velocity of the rotor wouldtransfer to the impeller, via the coupled shafts, and would be of thesame values.

In some examples of fluid pump systems, a motor shaft (e.g., a rotor)can be axially coupled to an impeller shaft via a magnetic coupling.Magnetic couplings transfer torque between two shafts without physicalcontact between the shafts. In some examples, the magnetic coupling canbe in the form of an inner hub fastened to a first shaft (e.g., animpeller shaft) and an outer hub fastened to a second shaft (e.g., arotor shaft). In the example outer hub, there are a series of magnets(e.g., bar magnets) positioned to surround the example inner hub witheach magnet having an opposite charge of the preceding magnet in theseries. In the inner hub, a similar series of magnets are positionedaround an axis of rotation of the first shaft. In some examples, theouter hub and inner hub have the same number of magnets. Because magnetsof opposite charges are attracted to each other via magnetic fields,when the outer hub is positioned around the inner hub, a rotation of theouter hub causes the inner hub to rotate at the same rate. In otherwords, the example inner hub and the example outer hub are rotatablyinterlocked. This type of magnetic coupling can be referred to as aco-axial magnetic coupling. Because there is no physical contact betweenthe inner hub and outer hub of the co-axial magnetic coupling, acontainment barrier can be fastened to the housing surrounding the innerhub such that no fluid can pass from the inner hub side to the outer hubside.

Example Aircraft and Engines that May Implement the Examples DisclosedHerein

For the figures disclosed herein, identical numerals indicate the sameelements throughout the figures. Referring now to the drawings, FIG. 1is a side view of one embodiment of an aircraft 10. As shown, in severalembodiments, the aircraft 10 includes a fuselage 12 and a pair of wings14 (one is shown) extending outward from the fuselage 12. In theillustrated embodiment, a gas turbine engine 100 is supported on eachwing 14 to propel the aircraft through the air during flight.Additionally, as shown, the aircraft 10 includes a vertical stabilizer16 and a pair of horizontal stabilizers 18 (one is shown). However, inalternative embodiments, the aircraft 10 may include any other suitableconfiguration, such as any other suitable number or type of engines.

Furthermore, the aircraft 10 may include a thermal management system 200for transferring heat between fluids supporting the operation of theaircraft 10. More specifically, the aircraft 10 may include one or moreaccessory systems configured to support the operation of the aircraft10. For example, in some embodiments, such accessory systems include alubrication system that lubricates components of the engines 100, acooling system that provides cooling air to components of the engines100, an environmental control system that provides cooled air to thecabin of the aircraft 10, and/or the like. In such embodiments, thethermal management system 200 is configured to transfer heat to and/orfrom one or more fluids supporting the operation of the aircraft 10(e.g., the oil of the lubrication system, the air of the cooling systemand/or the environmental control system, and/or the like) from and/or toone or more other fluids supporting the operation of the aircraft 10(e.g., the fuel supplied to the engines 100). However, in alternativeembodiments, the thermal management system 200 may be configured totransfer heat between any other suitable fluids supporting the operationof the aircraft 10.

The configuration of the aircraft 10 described above and shown in FIG. 1is provided only to place the present subject matter in an exemplaryfield of use. Thus, the present subject matter may be readily adaptableto any manner of aircraft and/or any other suitable heat transferapplication.

FIG. 2 is a schematic cross-sectional view of one embodiment of a gasturbine engine 100. In the illustrated embodiment, the engine 100 isconfigured as a high-bypass turbofan engine. However, in alternativeembodiments, the engine 100 may be configured as a propfan engine, aturbojet engine, a turboprop engine, a turboshaft gas turbine engine, orany other suitable type of gas turbine engine.

In general, the engine 100 extends along an axial centerline 102 andincludes a fan 104, a low-pressure (LP) spool 106, and a high pressure(HP) spool 108 at least partially encased by an annular nacelle 110.More specifically, the fan 104 may include a fan rotor 112 and aplurality of fan blades 114 (one is shown) coupled to the fan rotor 112.In this respect, the fan blades 114 are circumferentially spaced apartand extend radially outward from the fan rotor 112. Moreover, the LP andHP spools 106, 108 are positioned downstream from the fan 104 along theaxial centerline 102. As shown, the LP spool 106 is rotatably coupled tothe fan rotor 112, thereby permitting the LP spool 106 to rotate the fanblades 114. Additionally, a plurality of outlet guide vanes or struts116 circumferentially spaced apart from each other and extend radiallybetween an outer casing 118 surrounding the LP and HP spools 106, 108and the nacelle 110. As such, the struts 116 support the nacelle 110relative to the outer casing 118 such that the outer casing 118 and thenacelle 110 define a bypass airflow passage 120 positioned therebetween.

The outer casing 118 generally surrounds or encases, in serial floworder, a compressor section 122, a combustion section 124, a turbinesection 126, and an exhaust section 128. In some examples, thecompressor section 122 may include a low-pressure (LP) compressor 130 ofthe LP spool 106 and a high-pressure (HP) compressor 132 of the HP spool108 positioned downstream from the LP compressor 130 along the axialcenterline 102. Each compressor 130, 132 may, in turn, include one ormore rows of stator vanes 134 interdigitated with one or more rows ofcompressor rotor blades 136. As such, the compressors 130, 132 define acompressed air flow path 133 extending therethrough. Moreover, in someexamples, the turbine section 126 includes a high-pressure (HP) turbine138 of the HP spool 108 and a low-pressure (LP) turbine 140 of the LPspool 106 positioned downstream from the HP turbine 138 along the axialcenterline 102. Each turbine 138, 140 may, in turn, include one or morerows of stator vanes 142 interdigitated with one or more rows of turbinerotor blades 144.

Additionally, the LP spool 106 includes the low-pressure (LP) shaft 146and the HP spool 108 includes a high pressure (HP) shaft 148 positionedconcentrically around the LP shaft 146. In such embodiments, the HPshaft 148 rotatably couples the turbine rotor blades 144 of the HPturbine 138 and the compressor rotor blades 136 of the HP compressor 132such that rotation of the turbine rotor blades 144 of the HP turbine 138rotatably drives the compressor rotor blades 136 of the HP compressor132. As shown, the LP shaft 146 is directly coupled to the turbine rotorblades 144 of the LP turbine 140 and the compressor rotor blades 136 ofthe LP compressor 130. Furthermore, the LP shaft 146 is coupled to thefan 104 via a gearbox 150. In this respect, the rotation of the turbinerotor blades 144 of the LP turbine 140 rotatably drives the compressorrotor blades 136 of the LP compressor 130 and the fan blades 114.

In some examples, the engine 100 may generate thrust to propel anaircraft. More specifically, during operation, air (indicated by arrow152) enters an inlet portion 154 of the engine 100. The fan 104 suppliesa first portion (indicated by arrow 156) of the air 152 to the bypassairflow passage 120 and a second portion (indicated by arrow 158) of theair 152 to the compressor section 122. The second portion 158 of the air152 first flows through the LP compressor 130 in which the compressorrotor blades 136 therein progressively compress the second portion 158of the air 152. Next, the second portion 158 of the air 152 flowsthrough the HP compressor 132 in which the compressor rotor blades 136therein continue to progressively compress the second portion 158 of theair 152. The compressed second portion 158 of the air 152 issubsequently delivered to the combustion section 124. In the combustionsection 124, the second portion 158 of the air 152 mixes with fuel andburns to generate high-temperature and high-pressure combustion gases160. Thereafter, the combustion gases 160 flow through the HP turbine138 which the turbine rotor blades 144 of the HP turbine 138 extract afirst portion of kinetic and/or thermal energy therefrom. This energyextraction rotates the HP shaft 148, thereby driving the HP compressor132. The combustion gases 160 then flow through the LP turbine 140 inwhich the turbine rotor blades 144 of the LP turbine 140 extract asecond portion of kinetic and/or thermal energy therefrom. This energyextraction rotates the LP shaft 146, thereby driving the LP compressor130 and the fan 104 via the gearbox 150. The combustion gases 160 thenexit the engine 100 through the exhaust section 128.

As mentioned above, the aircraft 10 may include a thermal managementsystem 200 for transferring heat between fluids supporting the operationof the aircraft 10. In this respect, the thermal management system 200may be positioned within the engine 100. For example, as shown in FIG. 2, the thermal management system 200 is positioned within the outercasing 118 of the engine 100. However, in alternative examples, thethermal management system 200 may be positioned at any other suitablelocation within the engine 100.

Furthermore, in some examples, the engine 100 defines a third-streamflow path 170. In general, the third-stream flow path 170 extends fromthe compressed air flow path 133 defined by the compressor section 122to the bypass airflow passage 120. In this respect, the third-streamflow path 170 allows compressed a portion of the compressed air 158 fromthe compressor section 122 to bypass the combustion section 124. Morespecifically, in some examples, the third-stream flow path 170 maydefine a concentric or non-concentric passage relative to the compressedair flow path 170 downstream of one or more of the compressors 130, 132or the fan 104. The third-stream flow path 170 may be configured toselectively remove a portion of compressed air 158 from the compressedair flow path 170 via one or more variable guide vanes, nozzles, orother actuable flow control structures. In addition, as will bedescribed below, in some embodiments, the thermal management system 200may transfer heat to the air flowing through the third-stream flow path170. However, a pressure and/or a flow rate of a fluid (e.g., a heatexchange fluid such as a supercritical fluid (e.g., supercritical carbondioxide (sCO₂), etc.)) within the thermal management system 200 limits arate at which thermal energy is transferred between the air and the heatexchange fluid. Additionally, it is advantageous for the thermalmanagement system 200 to produce the pressure and/or the flow rate withcomponents (e.g., pump systems) that minimize and/or otherwise reduce aphysical size of the thermal management system 200 and/or the components(e.g., pump systems) included therein. Moreover, the thermal managementsystem 200 may ensure that the heat exchange fluid is free ofcontaminants when thermal energy is to be transferred.

The configuration of the gas turbine engine 100 described above andshown in FIG. 2 is provided only to place the present subject matter inan exemplary field of use. Thus, the present subject matter may bereadily adaptable to any manner of gas turbine engine configuration,including other types of aviation-based gas turbine engines,marine-based gas turbine engines, and/or land-based/industrial gasturbine engines.

Example Thermal Management Systems that May Implement the ExamplesDisclosed Herein

FIG. 3 is a schematic view of an example implementation of the thermalmanagement system 200 for transferring heat between fluids. In general,the thermal management system 200 will be discussed in the context ofthe aircraft 10 and the gas turbine engine 100 described above and shownin FIGS. 1 and 2 . However, the disclosed thermal management system 200may be implemented within any aircraft having any other suitableconfiguration and/or any gas turbine engine having any other suitableconfiguration.

As shown, the thermal management system 200 includes a thermal transportbus 202. Specifically, in several examples, the thermal transport bus202 is configured as one or more fluid conduits through which a fluid(e.g., a heat exchange fluid) flows. As will be described below, theheat exchange fluid flows through various heat exchangers such that heatis added to and/or removed from the heat exchange fluid. In thisrespect, the heat exchange fluid may be any suitable fluid, such assupercritical carbon dioxide. Moreover, in such examples, the thermalmanagement system 200 includes a pump 204 configured to pump the heatexchange fluid through the thermal transport bus 202.

Additionally, the thermal management system 200 includes one or moreheat source heat exchangers 206 arranged along the thermal transport bus202. More specifically, the heat source heat exchanger(s) 206 is fluidlycoupled to the thermal transport bus 202 such that the heat exchangefluid flows through the heat source heat exchanger(s) 206. In thisrespect, the heat source heat exchanger(s) 206 is configured to transferheat from fluids supporting the operation of the aircraft 10 to the heatexchange fluid, thereby cooling the fluids supporting the operation ofthe aircraft 10. Thus, the heat source heat exchanger(s) 206 adds heatto the heat exchange fluid. Although FIG. 3 illustrates two heat sourceheat exchangers 206, the thermal management system 200 may include asingle heat source heat exchanger 206 or three or more heat source heatexchangers 206.

The heat source heat exchanger(s) 206 may correspond to any suitableheat exchanger(s) that cool a fluid supporting the operation of theaircraft 10. For example, in one embodiment, at least one of the heatexchangers 206 is a heat exchanger(s) of the lubrication system(s) ofthe engine(s) 100. In such an example, this heat exchanger(s) 206transfers heat from the oil lubricating the engine(s) 100 to the heattransfer fluid. In another example, at least one of the heat exchangers206 is a heat exchanger(s) of the cooling system of the engine(s) 100.In such an example, this heat exchanger(s) 206 transfers heat from thecooling air bled from the compressor section(s) 122 (or a compressordischarge plenum) of the engine(s) 100 to the heat transfer fluid.However, in alternative examples, the heat source heat exchanger(s) 206may correspond to any other suitable heat exchangers that cool a fluidsupporting the operation of the aircraft 10.

Furthermore, the thermal management system 200 includes a plurality ofheat sink heat exchangers 208 arranged along the thermal transport bus202. More specifically, the heat sink heat exchangers 208 are fluidlycoupled to the thermal transport bus 202 such that the heat exchangefluid flows through the heat sink heat exchangers 208. In this respect,the heat sink heat exchangers 208 are configured to transfer heat fromthe heat exchange fluid to other fluids supporting the operation of theaircraft 10, thereby heating the other fluids supporting the operationof the aircraft 10. Thus, the heat sink heat exchangers 208 remove heatfrom the heat exchange fluid. Although FIG. 3 illustrates two heat sinkheat exchangers 208, the thermal management system 200 may include threeor more heat sink heat exchangers 208.

The heat sink heat exchangers 208 may correspond to any suitable heatexchangers that heat a fluid supporting the operation of the aircraft10. For example, at least of one of the heat exchangers 208 is a heatexchanger(s) of the fuel system(s) of the engine(s) 100. In such anexample, the fuel system heat exchanger(s) 208 transfers heat from theheat transfer fluid to the fuel supplied to the engine(s) 100. Inanother embodiment, at least one of the heat exchangers 208 is a heatexchanger(s) in contact with the air 156 flowing through the bypassairflow passage(s) 120 of the engine(s) 100. In such an example, thisheat exchanger(s) 208 transfers heat from the heat exchange fluid to theair 156 flowing through the bypass airflow passage(s) 120.

In several examples, one or more of the heat exchangers 208 areconfigured to transfer heat to the air flowing through the third-streamflow path 170. In such examples, the heat exchanger(s) 208 is in contactwith the air flow through the third-stream flow path 170. Thus, heatfrom the heat exchange fluid flowing through the thermal transport bus202 may be transferred to the air flow through the third-stream flowpath 170. The use of the third-stream flow path 170 as a heat sink forthe thermal management system 200 provides one or more technicaladvantages. For example, the third-stream flow path 170 provides greatercooling than other sources of bleed air because a larger volume of airflows through the third-stream flow path 170 than other bleed air flowpaths. Moreover, the air flowing through third-stream flow path 170 iscooler than the air flowing through other bleed air flow paths and thecompressor bleed air. Additionally, the air in the third-stream flowpath 170 is pressurized, thereby allowing the heat exchanger(s) 208 tobe smaller than heat exchangers relying on other heat sinks within theengine. Furthermore, in embodiments in which the engine 100 is unducted,using the third-stream flow path 170 as a heat sink does not increasedrag on the engine 100 unlike the use of ambient air (e.g., a heatexchanger in contact with air flowing around the engine 100). However,in alternative embodiments, the heat sink heat exchangers 208 maycorrespond to any other suitable heat exchangers that heats a fluidsupporting the operation of the aircraft 10.

Moreover, in several embodiments, the thermal management system 200includes one or more bypass conduits 210. Specifically, as shown, eachbypass conduit 210 is fluidly coupled to the thermal transport bus 202such that the bypass conduit 210 allows at least a portion of the heatexchange fluid to bypass one of the heat exchangers 206, 208. In someexamples, the heat exchange fluid bypasses one or more of the heatexchangers 206, 208 to adjust the temperature of the heat exchange fluidwithin the thermal transport bus 202. The flow of example heat exchangefluid through the bypass conduit(s) 210 is controlled to regulate thepressure of the heat exchange fluid within the thermal transport bus202. In the illustrated example of FIG. 3 , each heat exchanger 206, 208has a corresponding bypass conduit 210. However, in alternativeembodiments, any number of heat exchangers 206, 208 may have acorresponding bypass conduit 210 so long as there is at least one bypassconduit 210.

Additionally, in several examples, the thermal management system 200includes one or more heat source valves 212 and one or more heat sinkvalves 214. In general, each heat source valve 212 is configured tocontrol the flow of the heat exchange fluid through a bypass conduit 210that bypasses a heat source heat exchanger 206. Similarly, each heatsink valve 214 is configured to control the flow of the heat exchangefluid through a bypass conduit 210 that bypasses a heat sink heatexchanger 208. In this respect, each valve 212, 214 is fluidly coupledto the thermal transport bus 202 and a corresponding bypass conduit 210.As such, each valve 212, 214 may be moved between fully and/or partiallyopened and/or closed positions to selectively occlude the flow of heatexchange through its corresponding bypass conduit 210.

The valves 212, 214 are controlled based on the pressure of the heatexchange fluid within the thermal transport bus 202. More specifically,as indicated above, in certain instances, the pressure of the heatexchange fluid flowing through the thermal transport bus 202 may falloutside of a desired pressure range. When the pressure of the heatexchange fluid is too high, the thermal management system 200 may incuraccelerated wear. In this respect, when the pressure of the heatexchange fluid within the thermal transport bus 202 exceeds a maximum orotherwise increased pressure value, one or more heat source valves 212open. In such instances, at least a portion of the heat exchange fluidflows through the bypass conduits 210 instead of the heat source heatexchanger(s) 206. Thus, less heat is added to the heat exchange fluid bythe heat source heat exchanger(s) 206, thereby reducing the temperatureand, thus, the pressure of the fluid. In several embodiments, themaximum pressure value is between 3800 and 4000 pounds per square inchor less. In some embodiments, the maximum pressure value is between 2700and 2900 pounds per square inch, such as 2800 pounds per square inch. Inother embodiments, the maximum pressure value is between 1300 and 1500pounds per square inch, such as 1400 pounds per square inch. Suchmaximum pressure values generally prevent the thermal management system200 from incurring accelerated wear.

In some examples, the maximum pressure value is set prior to and/orduring operation based on parameters (e.g., materials utilized, pump 204design, aircraft 10 design, gas turbine engine 100 design, heat exchangefluid, etc.) associated with the thermal management system 200. Theexample maximum pressure value can be adjusted relative to the pressurecapacities of the thermal transport bus 202, the pump 204, the heatexchangers 206, 208, the bypass conduit(s) 210, and/or the valves 212,214. Some examples of pump 204 architecture that influence examplemaximum pressure capacities are described in greater detail below.

Conversely, when the pressure of the heat exchange fluid is too low, thepump 204 may experience operability problems and increased wear. Assuch, when the pressure of the heat exchange fluid within the thermaltransport bus falls below a minimum or otherwise reduced pressure value,one or more thermal sink valves 214 open. In such instances, at least aportion of the heat exchange fluid flows through the bypass conduits 210instead of the heat sink heat exchangers 208. Thus, less heat is removedfrom the heat exchange fluid by the heat sink heat exchangers 208,thereby increasing the temperature and, thus, the pressure of the fluid.In several embodiments, the minimum pressure value is 1070 pounds persquare inch or more. In some embodiments, the minimum pressure value isbetween 1150 and 1350 pounds per square inch, such as 1250 pounds persquare inch. In other embodiments, the minimum pressure value is between2400 and 2600 pounds per square inch, such as 2500 pounds per squareinch. Such minimum pressure values are generally utilized when the heatexchange fluid in a supercritical state (e.g., when the heat exchangefluid is carbon dioxide).

As such, the thermal management system 200 may be configured to operatesuch that the pressure of the heat transport fluid is maintained with arange extending between the minimum and maximum pressure values. In someexamples, the range extends from 1070 to 4000 pounds per square inch.Specifically, in one example, the range extends from 1250 to 1400 poundsper square inch. In another embodiment, range extends from 2500 to 2800pounds per square inch.

Accordingly, the operation of the pump 204 and the valves 212, 214allows the disclosed thermal management system 200 to maintain thepressure of the heat exchange fluid within the thermal transport bus 202within a specified range of values as the thermal load placed on thethermal management system 200 varies.

Furthermore, the example pump 204 drives the flow of the heat exchangefluid through the thermal management system 200. In some examples, thethermal management system 200 includes one pump 204 or multiple pumps204 depending on the desired flow rate, delta pressure across the pump204, and/or the kinetic energy loss of the heat exchange fluid in thethermal transport bus 202. For example, the pump 204 may increase theoutput pressure head to accelerate the flow of the heat exchange fluidto a first flowrate. As the heat exchange fluid passes through thethermal transport bus 202, the example kinetic energy of the heatexchange fluid dissipates due to friction, temperature variations, etc.Due to the kinetic energy losses, the heat exchange fluid decelerates toa second flow rate at some point upstream of the pump 204. If theexample second flow rate is below a desired operating flow rate of theheat exchange fluid, then the pump 204 can either be of a differentarchitecture that outputs a higher first flow rate, or one or moreadditional pumps 204 can be included in the thermal management system200. Variations on example pump 204 architectures are described ingreater detail below.

FIG. 4 illustrates an example thermal transport bus pump 400 (e.g., amagnetically driven pump, a canned motor pump, a fluid pump, a sCO₂pump, the pump 204 of FIG. 3 , etc.). In the illustrated example of FIG.4 , the thermal transport bus pump 400 drives a fluid (e.g., heatexchange fluid such as sCO₂, etc.) through one or more fluid conduits402 connected to a flowline (e.g., the thermal transport bus 202 of FIG.3 ). Specifically, the fluid flows through an inlet pipe 404 andencounters an impeller 406 (e.g., a compressor wheel) that rotates todrive the fluid through a compressor collector 408 (e.g., a volutehousing) fluidly coupled to the fluid conduit(s) 402. In turn, the fluidconduit(s) 402 can feed the fluid to one or more heat exchangers (e.g.,the heat source exchanger 206 and/or the heat sink exchanger 208 of FIG.3 ). Accordingly, the thermal transport bus pump 400 can pump the fluidto manage a thermal energy of working fluids associated with theaircraft 10 of FIG. 1 , the gas turbine engine 100 of FIG. 2 , and/orany other suitable system.

In the illustrated example of FIG. 4 , the thermal transport bus pump400 includes a motor 410 positioned in a motor housing 412. The motor410 indirectly drives a rotation of the impeller 406, as discussed infurther detail below. In FIG. 4 , the motor 410 is an induction motoroperatively coupled to a variable frequency drive (VFD) (not shown) viaa feedthrough connector 414 coupled to the motor housing 412. The VFDcan be operatively coupled to controlling circuitry, such as a fullauthority digital engine control (FADEC) (not shown), that controls arotational speed of the motor 410. For example, the controllingcircuitry can operate the motor 410 based on a pressure and/or atemperature of the fluid in the fluid conduit(s) 402 and/or in thethermal transport bus pump 400. In some examples, the controllingcircuitry can operate the motor 410 based on a pressure and/or atemperature of the working fluids affected by the fluid. Additionally oralternatively, the controlling circuitry can operate the motor 410 basedon vibration measurements obtained by accelerometers operatively coupledto the thermal transport bus pump 400 and/or the fluid conduit(s) 402.

In FIG. 4 , the motor housing 412 is at least partially surrounded by acooling jacket 416 to prevent the motor 410 from overheating. An aft endof the motor housing 412 is coupled to an aft bearing housing 418. Aforward end of the motor housing 412 is coupled to an intermediatebearing housing 420 via bolts 422. Further, the intermediate bearinghousing 420 is coupled to a coupling housing 424 opposite the motorhousing 412 via bolts 426. The coupling housing 424 is coupled to aforward bearing housing 428 opposite the intermediate bearing housing420 via bolts 430. Moreover, the forward bearing housing 428 is coupledto a backplate 432 and the compressor collector 408 on an opposite sideof the backplate 432 via bolts 434.

In the illustrated example of FIG. 4 , a rotor 436 of the motor 410 isfixedly coupled to a shaft 438. As such, the motor 410 drives a rotationof the shaft 438. An aft end of the shaft 438 is supported by a firstroller bearing 440 (e.g., a first rolling element bearing), which iscoupled to the aft bearing housing 418. Specifically, the first rollerbearing 440 is coupled to the aft bearing housing 418 via a firstbearing cup 442 and a bearing shim 444 positioned between the firstroller bearing 440 and the aft bearing housing 418. In the illustratedexample of FIG. 4 , a preload spring 446 is positioned between the firstbearing cup 442 and the bearing shim 444. Similarly, a forward end ofthe shaft 438 is supported by a second roller bearing 448 (e.g., asecond rolling element bearing) coupled to the intermediate bearinghousing 420. Specifically, the second roller bearing 448 is coupled tothe intermediate bearing housing 420 via a second bearing cup 449. Thefirst roller bearing 440 and the second roller bearing 448 are packedwith oil lubricant(s) (e.g., grease, motor oil, etc.) to reduce aresistance against the rotation of the shaft 438 and reduce wearencountered by the bearings 440, 448 as the shaft 438 rotates.

In the illustrated example of FIG. 4 , the forward end of the shaft 438extends at least partially through the intermediate bearing housing 420.An aft end of a first magnetic coupling 450 (e.g., a female magneticcoupling) is positioned around the forward end of the shaft 438. Tocouple the shaft 438 and the first magnetic coupling 450, a retentionbolt 451 is inserted through the aft end of the first magnetic coupling450 and the forward end of the shaft 438. Specifically, a width of ahead 453 of the retention bolt 451 is greater than a width of an orifice455 in the first magnetic coupling 450 through which the retention bolt451 extends. As a result, the shaft 438 drives a rotation of the firstmagnetic coupling 450.

In the illustrated example of FIG. 4 , the first magnetic coupling 450is positioned around a barrier can 452 (e.g., a shroud). To couple thebarrier can 452 to the forward bearing housing 428, a barrier canretainer 454 (e.g., a retainer ring) is positioned around a flange 456of the barrier can 452 and coupled to an aft end of the forward bearinghousing 428 via bolts 458. Further, an O-ring 459 is positioned betweenthe flange 456 of the barrier can 452 and the barrier can retainer 454.The barrier can 452 hermetically seals the aft end of the forwardbearing housing 428 and, in turn, prevents the fluid from escaping. Assuch, the barrier can 452 prevents the fluid from flowing past thecoupling housing 424 and mixing with other fluids, such as the oillubricant of the first roller bearing 440 and/or the second rollerbearing 448, which would otherwise prevent thermal energy from beingsafely transferred between the fluid and a working fluid. Additionallyor alternatively, the barrier can 452 can hermetically seal the motorhousing 412 to prevent the oil lubricant from mixing with andcontaminating the fluid.

In the illustrated example of FIG. 4 , the barrier can 452 is positionedaround a second magnetic coupling 460 (e.g., a male magnetic coupling),which is magnetically coupled to the first magnetic coupling 450.Specifically, opposite magnetic poles of the first magnetic coupling 450and the second magnetic coupling 460 are aligned on opposite sides ofthe barrier can 452 to magnetically couple the first magnetic coupling450 to the second magnetic coupling 460. As a result, the first magneticcoupling 450 and the second magnetic coupling 460 are rotatablyinterlocked. Accordingly, the first magnetic coupling 450 can drive arotation of the second magnetic coupling 460. In some examples, thecoupling housing 424 includes a vent 461 to enable a fluid (e.g.,hydrogen, air, etc.) to circulate into and out of the coupling housing424. In turn, as the barrier can 452 produces thermal energy as a resultof encountering the rotating magnetic fields produced by the firstmagnetic coupling 450 and the second magnetic coupling 460, the fluidcan absorb the heat from the barrier can 452 to prevent the barrier can452 from melting. In some examples, a fan drives the fluid circulationthrough the vent 461 in the coupling housing 424. In some otherexamples, the vent 461 is open to atmospheric air, or another fluidenclosure, which provides the fluid to absorb thermal energy from thebarrier can 452.

In the illustrated example of FIG. 4 , the second magnetic coupling 460is coupled to a tie rod 462 via a top hat 464. The tie rod 462 extendsthrough the forward bearing housing 428 and the backplate 432 to coupleto the impeller 406. Additionally, the second magnetic coupling 460 iscoupled to and/or extends from a shaft 466 positioned around the tie rod462. Similarly, the shaft 466 extends through the forward bearinghousing 428 and the backplate 432 to couple to the impeller 406. As aresult, the tie rod 462 and the shaft 466 cause the impeller 406 torotate with the second magnetic coupling 460 and pump the fluid.

In the illustrated example of FIG. 4 , an axial portion 468 of the shaft466 is supported by journal bearing assemblies 470. Further, a radialportion 472 of the shaft 466 is supported by a thrust bearing assembly474. For example, the journal bearing assemblies 470 and/or the thrustbearing assembly 474 can include foil bearings. In some examples, thejournal bearing assemblies 470 and the thrust bearing assembly 474 arecoupled to the forward bearing housing 428 via bolts. Additionally oralternatively, the thrust bearing assembly 474 can be coupled to one ofthe journal bearing assemblies 470.

In the illustrated example of FIG. 4 , the thermal transport bus pump400 includes a secondary flow network having an inlet 475 in the forwardbearing housing 428. Specifically, in the secondary flow network, thefluid enters the forward bearing housing 428 and flows between theradial portion 472 of the shaft 466 and the thrust bearing assembly 474.Further, in the secondary flow network, a first portion of the fluidflows around the shaft 466 and into the compressor collector 408 betweenthe impeller 406 and the backplate 432. A second portion of the fluid inthe secondary flow network flows around the shaft 466 towards thebarrier can 452. A separation between an aft end of the second magneticcoupling 460 and the barrier can 452 enables the fluid to flow past thesecond magnetic coupling 460 and back through the shaft 466 towards theimpeller 406. Further, the shaft 466 includes a duct 476 that guides thefluid flowing therethrough between the backplate 432 and the impeller406 causing the fluid to enter the compressor collector 408.Accordingly, as the motor 410 drives the rotation of the shaft 438, theimpeller 406 pumps the fluid through the fluid conduit(s) 402.

In some examples, the thermal transport bus pump 400 includes means forhousing a fluid. For example, the means for housing may be implementedby the compressor collector 408, the forward bearing housing 428, and/orthe backplate 432.

In some examples, the thermal transport bus pump 400 includes means forcompressing the fluid. For example, the means for compressing the fluidmay be implemented by the impeller 406.

In some examples, the thermal transport bus pump 400 includes means forsealing the means for housing. For example, the means for sealing may beimplemented by the barrier can 452.

Radially Coupled Pump Systems for Pressurizing Fluid in Closed LoopSystems

The operations of some example fluid pump systems and centrifugal fluidpump systems have an electric motor aligned axially with an impeller(e.g., impeller 406) as described in reference to FIG. 4 above. In suchexample fluid pumps, the torque and angular velocity of a motor shaft(e.g., rotor shaft 438) is transferred directly to an impeller shaft(e.g., impeller shaft 466), and ultimately, to the impeller. Forexample, if a motor (e.g., motor 410) supplies 2000 Watts (W) ofmechanical power to the rotor shaft, and the rotor shaft is spinning atan angular rate of 3600 rotations per minute (rpm), then the torque therotor generates is 5.31 Newton-meters (Nm). In this example, since therotor is axially aligned with and coupled to the impeller via theimpeller shaft, the impeller will also have an angular velocity of 3600rpm (378 radians per second (rad/s)) and a torque of 5.31 Nm.

In some examples, fluid pumps in an axial configuration, such as thermaltransport bus pump 400 (“axially-coupled pump 400”) of FIG. 4 describedabove, are limited in the amount of angular velocity the impeller canconvert to a fluid flow rate. The example angular velocity of theimpeller is limited based on the available mechanical power the electricmotor supplies to the pump system (e.g., axially coupled pump 400). Inother words, the electric motor induces a first angular velocity of therotor shaft that is substantially similar to (e.g., within one percentof) a second angular velocity of the impeller. Therefore, the power ofthe motor limits the flow rate of a fluid (e.g., a heat exchange fluidsuch as a supercritical fluid (e.g., supercritical carbon dioxide(sCO₂), etc.) exiting the pump 400. For example, the thermal managementsystem 200 of FIG. 3 on an aircraft (e.g., aircraft 10 of FIG. 1 ) mayinclude the axially coupled pump 400 to pressurize the fluid up to afirst pressure (e.g., 1450 force pounds per square inch (psi), 1475 psi,1500 psi, etc.) associated with a first angular velocity (e.g., 4800rpm, 5000 rpm, 5200 rpm, etc.) of the impeller. However, the axiallycoupled pump 400 of the above example might not be able to pressurizethe example sCO₂ to a pressure that is sufficient to maintain thesupercritical state of the fluid due to thermal energy losses in theexample thermal management system 200. A larger and more powerful motorwould have to be incorporated into the axially coupled pump 400, whichwould take up more space and add additional weight to the system. If theaxially coupled pump 400 of the above example is able to pressurize theheat exchange fluid up to a second pressure (e.g., 1550 psi, 1575 psi,1600 psi, etc.) associated with the first angular velocity of theimpeller, then the motor (e.g., motor 410) of the axially coupled pump400 might require maintenance or replacement after a first time period(e.g., one year) of operation.

In the examples disclosed herein, a radially coupled pump system canoutput a higher angular velocity of an impeller with a same (e.g.,substantially similar) motor and/or same power output as the motor 410of the axially coupled pump 400. In the examples disclosed herein, theradially coupled pump system can also output a same (e.g., substantiallysimilar) angular velocity of the impeller with a smaller motor and/orsmaller power output as the motor 410 of the axially coupled pump 400.In the examples disclosed herein, the radially coupled pump system canalso decrease the axial length of the pump relative to the axiallycoupled pump 400, thereby saving space in a system (e.g., the thermalmanagement system 200 of FIG. 3 ) that uses the radially coupled pumpsystem.

FIG. 5 illustrates a cross-sectional view of a radially coupled pumpsystem 500 for pressurizing fluid (e.g., a heat exchange fluid such as asupercritical fluid (e.g., sCO₂, etc.)) in a system (e.g., thermalmanagement system 200 of FIG. 3 ). As shown in FIG. 5 , the radiallycoupled pump system 500 (“pump system 500”) includes a pump 502 and anelectric motor 504. In some examples, the pump system 500 is used topump sCO₂ through a thermal management system on an aircraft (e.g.,aircraft 10 of FIG. 1 ) and/or a gas turbine engine (e.g., gas turbineengine 100 of FIG. 2 ). In some examples, the electric motor 504 of thepump system 500 includes a stator 506, a rotor 508, radial motorbearing(s) 510, a motor housing 512, a cooling jacket 514, a couplinghousing 516, and a driver wheel 518.

The example electric motor 504 of pump system 500 illustrated in FIG. 5includes the stator 506 and the rotor 508. In some examples, the stator506 includes field magnets (e.g., electromagnets or permanent magnets)that generate magnetic field(s) based on an electric current (e.g.,direct current or alternating current) passing through various theelectromagnets of the stator 506. The example stator 506 generates afirst set of magnetic fields that apply a force (e.g., Lorentz force) ona second set of magnetic fields that the rotor 508 generates. Theexample rotor 508 generates the second set of magnetic fields viapermanent magnets or electromagnets. Since the stator 506 is stationaryand fixed in place, the force causes the example rotor 508 to rotate andto produce a torque.

The example electric motor 504 of pump system 500 includes radial motorbearings 510 that support a weight of the rotor shaft 508 and keep therotor 508 in radial and/or axial alignment. The example radial motorbearings 510 support a radial load (e.g., weight) and a thrust load ofthe rotor 508. In some examples, the radial motor bearings 510 arerolling element bearings, such as angular contact ball bearings, hybridceramic bearings, taper roller bearings, deep groove single ballbearings, duplex ball bearings, spherical bearings, etc. In someexamples, the radial motor bearings 510 use liquid lubricant(s) (e.g.,grease, oil, etc.) to reduce friction and wear in rotating elements ofthe radial motor bearings 510. In some examples, the radial motorbearings 510 use a solid lubricant (e.g., silver coating) to reducefriction and wear of the rotating elements of the radial motor bearings510. In some examples, the radial motor bearings 510 are foil bearingsthat use pressurized air to create a non-contact barrier between therotor shaft and a sleeve of the radial motor bearings 510 atsufficiently high rotational speeds. Although the electric motor 504illustrated in FIG. 5 includes two radial motor bearings 510, one ormore radial motor bearings 510 can be used in the electric motor 504.

The example electric motor 504 of pump system 500 includes the motorhousing 512 to frame and/or otherwise support the stator 506, radialmotor bearing(s) 510, etc. In some examples, the motor housing 512 isadditively manufactured (e.g., via direct metal laser sintering (DMLS),three-dimensional printing, etc.) to accommodate custom geometries andconfigurations of the stator 506, the radial motor bearing(s) 510, thecooling jacket 514, etc.

Since the example stator 506 uses electromagnets to generate Eddycurrents, the example pump system 500 illustrated in FIG. 5 includes thecooling jacket 514 to dissipate heat that the stator 506 generatesduring operation. In some examples, the cooling jacket 514 ismechanically fixed to the motor housing 512 and includes cooling fins,vents, channels, etc., to transfer heat from the stator 506 to air,water, gas coolant, liquid coolant, etc. The example motor housing 512illustrated in FIG. 5 is an additively manufactured structure thatincludes the cooling jacket 514 as an additively manufactured portion ofthe motor housing 512 such that the cooling jacket 514 and the motorhousing 512 are the same additively manufactured part. The examplecooling jacket 514 illustrated in FIG. 5 is manufactured in conjunctionwith the motor housing 512 to surround the stator 506 and transfer heatfrom the stator 506 to air, water, gas coolant, liquid coolant, etc.,via cooling fins, vents, channels, etc.

The example electric motor 504 of the pump system 500 includes thecoupling housing 516 to support the radial motor bearing(s) 510 and/orother parts of the pump system 500. The example parts of the pump system500 that the coupling housing 516 supports are described in greaterdetail below. In some examples, the coupling housing 516 is manufacturedseparately from the motor housing 512 and is fixed to the motor housing512 via bolts, dowels, interference fits, and/or adhesives. In someexamples, the coupling housing 516 is additively manufactured as aportion of the motor housing 512, such that the coupling housing 516 andthe motor housing 512 are the same additively manufactured part.

The example electric motor 504 of the pump system 500 includes thedriver wheel 518 coupled to the rotor shaft 508. The example driverwheel 518 of the pump system 500 illustrated in FIG. 5 is connected tothe rotor shaft 508 via one or more bolts such that there is a directtransference of torque from the rotor shaft 508 to the driver wheel 518.For example, if the stator 506 generates a first torque to turn therotor 508 at a first angular velocity, then the driver wheel 518 alsorotates at the first angular velocity. The example driver wheel 518 isradially coupled to a follower wheel 520 to convert the first torque andthe first angular velocity to a second torque and a second angularvelocity that the follower wheel 520 outputs.

The example pump 502 of the pump system 500 illustrated in FIG. 5includes the follower wheel 520, radial coupling bearing(s) 521, acoupling shaft 522, an impeller shaft 524, a magnetic coupling 526, animpeller 528, radial pump bearing(s) 530, a thrust shaft 532, a thrustbearing 534, a barrier can 536, an outer hub 538, an inner hub 540, anda backplate 542. The driver wheel 518 and the follower wheel 520 of thepump system 500 illustrated in FIG. 5 can be gears (e.g., spur gears,helical gears, double helical gears, etc.) radially connected viainterlocking gear teeth or pulleys radially connected via a drive belt.In some examples, the gear teeth of the driver wheel 518 generate aforce on the gear teeth of the follower wheel 520. In some examples, thedrive belt contacting the driver wheel 518 generates a tension forcethat acts on the outer surface of the follower wheel 520. The exampleforce, tension force, and/or the example first torque that the driverwheel 518 generates and the example first angular velocity at which thedriver wheel 518 rotates are based on the mechanical power output of themotor 504.

Equation 1 below represents instantaneous mechanical power of the driverwheel 518 and/or the follower wheel 520 in terms of torque and angularvelocity:

P=τω.  (Eq. 1)

In Equation 1, P is power, τ is torque, and ω is angular velocity. Sincepower is conserved and since the driver wheel 518 and the follower wheel520 are radially coupled via gearing teeth and/or the drive belt, theinstantaneous power of the driver wheel 518 (P₁) is substantiallysimilar to (e.g., within 1% of) the instantaneous power of the followerwheel 520 (P₂). Thus, assuming there is no energy loss (e.g., 100%efficiency) between the driver wheel 518 and the follower wheel 520 dueto heat, vibration, bending, friction, drive belt creep, etc., thetransmission of torque and angular velocity between the driver wheel 518and the follower wheel 520 can be expressed with the following Equation2:

P ₁ =P ₂

τ₁ω₁=τ₂ω₂  (Eq. 2)

In Equation 2, τ₁ is the torque output of the driver wheel 518, ω₁ isthe angular velocity of the driver wheel 518, τ₂ is the torque output ofthe follower wheel 520, and ω₂ is the angular velocity of the followerwheel 520.

The example driver wheel 518 generates the first torque (τ₁) and theexample follower wheel 520 generates the second torque (τ₂). Thefollowing Equation 3 is used to determine the torque output of arotating wheel:

$\begin{matrix}{{\tau = {{F \times L} = {F \times \frac{D}{2}}}}.} & \left( {{Eq}.3} \right)\end{matrix}$

In Equation 3, F is the tangential force that the driver wheel 518and/or the follower wheel 520 produce, L is the length from axis ofrotation of the driver wheel 518 and/or the follower wheel 520 to thepoint where the force (F) acts (e.g., the radius of the driver wheel 518and/or the follower wheel 520), and D is the diameter of the driverwheel 518 and/or the follower wheel 520. The force F that the driverwheel 518 generates is the substantially similar (e.g., within 1%) tothe force value F that the follower wheel 520 generates due to Newton'sthird law with some loss due to heat, vibration, bending, friction,drive belt creep, etc. Thus, assuming no such loss occurs (e.g., 100%efficiency), Equation 2 and Equation 3 can be combined and reduced intoEquation 4 shown below:

$\begin{matrix}{\begin{matrix}{{\tau_{1}\omega_{1}} = {\tau_{2}\omega_{2}}} \\{{\left( {F \times \frac{D_{1}}{2}} \right)\omega_{1}} = {\left( {F \times \frac{D_{2}}{2}} \right)\omega_{2}}} \\{\omega_{2} = {\omega_{1}\frac{D_{1}}{D_{2}}}}\end{matrix}.} & \left( {{Eq}.4} \right)\end{matrix}$

Equation 4 can be used to determine the angular velocity of the followerwheel 520 and the impeller 528 based on the driver wheel 518 angularvelocity ω₁, the driver wheel 518 diameter D₁, and the follower wheel520 diameter D₂. Therefore, if the driver wheel 518 has a greaterdiameter than the follower wheel 520, the impeller 528 rotates at agreater rate than the rotor shaft 508 since the impeller 528 is axiallycoupled to the follower wheel 520 via the impeller shaft 524, themagnetic coupling 526, etc.

In the illustrated example of FIG. 5 , the driver wheel 518 has a largerdiameter than the follower wheel 520 to make the second angular velocityhigher than the first angular velocity according to Equation 4. Thefollower wheel 520 is fixed (e.g., via one or more bolts) to thecoupling shaft 522. The example radial coupling bearing(s) 521 support aweight that the coupling shaft 522 and other parts connected to thecoupling shaft 522 produce. The example coupling shaft 522 is configuredsuch that the coupling shaft 522 is axially coupled to the impellershaft 524 via the magnetic coupling 526. The example impeller shaft 524is also axially connected to the impeller 528 via one or more fastenings(e.g., bolts, rods, interference fits, etc.). Since the coupling shaft522, the magnetic coupling 526, and the impeller shaft 524 connect thefollower wheel 520 to the impeller 528, the second angular velocity ofthe follower wheel 520 is transferred directly to the impeller 528. Inother words, the impeller 528 and the follower wheel 520 are rotatablyinterlocked and rotate at the same rate.

The example pump 502 of the pump system 500 includes the radial pumpbearing(s) 530 to support a radial load that the impeller shaft 524produces. In some examples, the radial pump bearing(s) 530 are rollingelement bearings similar to the radial motor bearing(s) 510. In theexample pump system 500 illustrated in FIG. 5 , the radial pumpbearing(s) 530 are foil bearings. In some examples, the radial pumpbearing(s) 530 include a spring-loaded foil lining inside of a bearingsleeve. The example spring-loaded foil lining supports the weight of theimpeller shaft 524 as the impeller shaft 524 begins to rotate. As thesecond angular velocity of the impeller shaft 524 increases, the airpressure between the impeller shaft 524 and the spring-loaded foillining increases. As the second angular velocity continues to increase,the air pressure also increases until the air pressure pushes thespring-loaded foil lining outward from the axis of rotation. The exampleair gap that forms in the radial pump bearing 530 between the impellershaft 524 and a sleeve of the radial pump bearing 530 is what thensupports the weight of the impeller shaft 524.

The example radial pump bearing(s) 530 do not use fluid lubrication(e.g., oil lubricants) that can contaminate the heat exchange fluid.However, the example radial pump bearing(s) 530 (e.g., foil bearings)cannot support axial loads that the follower wheel 520, the couplingshaft 522, and/or the impeller shaft 524 generate. The example motorhousing 512 and the backplate 542 illustrated in FIG. 5 frame the thrustbearing 534 such that thrust bearing 534 supports the thrust load thatthe impeller shaft 524 generates. The example thrust shaft(s) 532 arefixed to the impeller shaft 524 and/or are otherwise rigidly extendingfrom the impeller shaft 524 perpendicular to the axis of rotation of theimpeller shaft 524. As the impeller shaft 524 rotates and transfers anaxial and/or thrust load to the thrust shaft(s) 532, the thrust bearing534 counteracts the axial load from the thrust shaft(s) 532 whileallowing the impeller shaft 524 to rotate with limited (e.g., less than1%) energy loss. While two thrust shafts 532 and one thrust bearing 534are illustrated in FIG. 5 , there can be two or more thrust shafts 532and/or one or more thrust bearings 534 in the pump system 500. In someexamples, the thrust bearing 534 can be a thrust ball bearing, acylindrical thrust roller bearing, a tapered roller thrust bearing, aspherical roller thrust bearing, a magnetic bearing, etc.

The example pump 502 of the pump system 500 illustrated in FIG. 5includes the magnetic coupling 526 to connect the coupling shaft 522 andthe impeller shaft 524. The example magnetic coupling 526 includes theouter hub 538 and the inner hub 540 both including permanent magnetsthat alternate in polarity around the axis of rotation. The exampleinner hub 540 is the male component of the magnetic coupling 526 andfits within the outer hub 538 (e.g., the female component). The magneticforces of the permanent magnets cause the coupling shaft 522 to transfertorque directly to the impeller shaft 524 such that the impeller shaft524 and the impeller 528 rotate at the same second angular velocity asthe follower wheel 520. The coupling shaft 522 is magnetically coupledto the impeller shaft 524 such that a gap exists between the male andfemale components. The example barrier can 536 (e.g., barrier can 452)is designed to fit within the gap without physically and/or magneticallyinterfering with the magnetic coupling 526.

The example barrier can 536 is fixed in the magnetic coupling 526, thecoupling housing 516, and/or the motor housing 512 to hermetically sealthe follower wheel 520, the coupling shaft 522, and the motor 504 fromthe fluid (e.g., a heat exchange fluid such as a supercritical fluid(e.g., sCO₂, etc.)). The example barrier can 536 also hermetically sealsexample oil(s) that the radial motor bearing(s) 510, the driver wheel518, the follower wheel 520, and/or the motor 504 use as lubricant fromcontaminating the heat exchange fluid. In some examples, the barrier can536 is of the same structure, materials, design, etc. as the barrier can452 of FIG. 4 . In some examples, the barrier can 536 of FIG. 5 is alsofixed to the coupling housing 516 and/or the motor housing 512 in thesame manner as the barrier can 452 of FIG. 4 , such as via a flange, abarrier can retainer ring, and/or bolts.

In some examples, the barrier can 536 includes an inner shell, a middlelayer, and an outer layer. In some examples, the inner layer and outerlayer are composed of various combinations of ceramic, polymer, orcomposite, and the middle layer is composed of metal electroformed overthe inner layer mandrel. Some further examples of the barrier can 536including materials, structure, design, etc. are described in greaterdetail in other sections of this document.

A radially coupled pump system 500 is disclosed herein. The examplesdisclosed herein include an electric motor 504 to drive a pump 502 via adriver wheel 518 axially connected to a rotor shaft 508. The examplesdisclosed herein further include a follower wheel 520 radially coupledto the driver wheel 518 via gearing or a drive belt. The examplesdisclosed herein further include that the follower wheel 520 is axiallyconnected to an impeller shaft 524 via a magnetic coupling 526. Theexamples disclosed herein further include that the driver wheel 518 hasa first diameter and the follower wheel 520 has a second diameter thatis smaller than the first diameter. Thus, the examples disclosed hereinfurther include that the driver wheel 518 rotates at a first angularvelocity and that the follower wheel 520 rotates at a second angularvelocity that is greater than the first angular velocity. The examplesdisclosed herein allow the motor 504 to be mounted above or belowportions of the pump 502 such that the pump system 500 saves space inthe axial direction relative to pump systems that are axially coupledand aligned (e.g., pump 400 of FIG. 4 ). The examples disclosed hereinoperate the electric motor 504 more efficiently, increase the lifetimeof the motor 504, increase the power density of the pump system 500, andincrease the maximum angular velocity of the impeller 528 relative tothose of the example pump 400 of FIG. 4 because the electric motor 504can output less mechanical power than the motor 410 to achieve the sameangular velocity of the impeller 406.

FIG. 6 illustrates a cross-sectional view of a radially coupled pumpsystem 600 for pressurizing fluid (e.g., a heat exchange fluid such as asupercritical fluid (e.g., sCO₂, etc.)) in a system (e.g., thermalmanagement system 200 of FIG. 3 ). As shown in FIG. 6 , the radiallycoupled pump system 600 (“pump system 600”) includes a pump 602 and anelectric motor 604. In some examples, the pump system 600 is used topump sCO₂ through a thermal management system on an aircraft (e.g.,aircraft 10 of FIG. 1 ) and/or a gas turbine engine (e.g., gas turbineengine 100 of FIG. 2 ). In some examples, the electric motor 604 of thepump system 600 includes a stator 606, a rotor 608, radial motorbearing(s) 610, a motor housing 612, a mounting rod 613, a coolingjacket 614, and a driver wheel 618.

The example electric motor 604 of pump system 600 illustrated in FIG. 6includes the stator 606 and the rotor 608. In some examples, the stator606 includes field magnets (e.g., electromagnets or permanent magnets)that generate magnetic field(s) based on an electric current (e.g.,direct current or alternating current) passing through various theelectromagnets of the stator 606. The example stator 606 generates afirst set of magnetic fields that apply a force (e.g., Lorentz force) ona second set of magnetic fields that the rotor 608 generates. Theexample rotor 608 generates the second set of magnetic fields viapermanent magnets or electromagnets. Since the stator 606 is stationaryand fixed in place, the force causes the example rotor 508 to rotate andto produce a torque.

The example stator 606 of the pump system 600 is structurally configuredto be fixed in place inside of the rotor 608. The example rotor 608rotates at a first angular velocity with a first torque similarly to therotor 508 of FIG. 5 . However, the rotor 608 encases the stator 606,whereas the stator 506 encases the rotor 508 of FIG. 5 . The examplestator 606 is fixed to the mounting rod 613. The example mounting rod613 is fixed to the motor housing 612 via one or more bolts. The examplemounting rod 613 also supports the radial motor bearing(s) 610 such thatan inner sleeve of the radial motor bearing(s) 610 is staticallyattached to the mounting rod 613.

The example electric motor 604 of pump system 600 includes radial motorbearing(s) 610 that support a weight of the rotor shaft 608 and/or thedriver wheel 618. The example radial motor bearing(s) 610 also keep therotor 608 and/or the driver wheel 618 in radial and/or axial alignment.The example radial motor bearing(s) 610 support a radial load (e.g.,weight) and a thrust load that the rotor 608 generates. In someexamples, the radial motor bearings 610 are rolling element bearings,such as angular contact ball bearings, hybrid ceramic bearings, taperroller bearings, deep groove single ball bearings, duplex ball bearings,spherical bearings, etc. In some examples, the radial motor bearings 610use liquid lubricant(s) (e.g., grease, oil, etc.) to reduce friction andwear in rotating elements of the radial motor bearings 610. In someexamples, the radial motor bearings 610 use a solid lubricant (e.g.,silver coating) to reduce friction and wear of the rotating elements ofthe radial motor bearings 610. In some examples, the radial motorbearings 610 are foil bearings that use pressurized air to create anon-contact barrier between the rotor shaft and a sleeve of the radialmotor bearings 610 at sufficiently high rotational speeds. Although theelectric motor 604 illustrated in FIG. 6 includes two radial motorbearings 610, one or more radial motor bearings 610 can be used in theelectric motor 604.

The example electric motor 604 of pump system 600 includes the motorhousing 612 to frame and/or otherwise support mounting rod 613, which inturn supports the stator 606, radial motor bearing(s) 510, etc. In someexamples, the motor housing 612 is additively manufactured (e.g., viadirect metal laser sintering (DMLS), three-dimensional printing, etc.)to accommodate custom geometries and configurations of the mounting rod613, the stator 606, the radial motor bearing(s) 610, the cooling jacket614, the rotor 608, the driver wheel 618, etc. The example motor housing612 illustrated in FIG. 6 can be additively manufactured to include themounting rod 613 and/or the cooling jacket 614 in the same fabricatedpart. Alternatively, the motor housing 612 can be additivelymanufactured separate from the mounting rod 613 and/or the coolingjacket 614 such that the geometric dimensions and tolerances of themotor housing 612 can appropriately accommodate the various parts of themotor 604, including the mounting rod 613 and/or the cooling jacket 614.Additionally or alternatively, the motor housing 612, the mounting rod613, and/or the cooling jacket 614 can be fabricated separately viasubtractive manufacturing methods.

Since the example stator 606 uses electromagnets to generate Eddycurrents, the example pump system 600 illustrated in FIG. 6 includes thecooling jacket 614 to dissipate heat that the stator 606 generatesduring operation. In some examples, the cooling jacket 614 ismechanically fixed to the stator 606 and/or the mounting rod 613 andincludes cooling fins, vents, channels, etc. to transfer heat from thestator 606 to air, water, gas coolant, liquid coolant, etc. The examplemounting rod 613 illustrated in FIG. 6 can be an additively manufacturedstructure that includes the cooling jacket 614 as an additivelymanufactured portion of the mounting rod 613 such that the coolingjacket 514 and the mounting rod 613 are the same additively manufacturedpart. The example cooling jacket 614 illustrated in FIG. 5 can bemanufactured in conjunction with the mounting rod 613 such that thestator 606 precisely fits around and/or couples to the cooling jacket614. In some examples, the cooling jacket 614 is manufactured inconjunction with the stator 606 such that the cooling jacket 614 and thestator 606 are the same part, and such that the cooling jacket 614transfers heat from the stator 606 to air, water, gas coolant, liquidcoolant, etc. via cooling fins, vents, channels, etc.

The example electric motor 604 of the pump system 600 includes thedriver wheel 618 coupled to the rotor shaft 608. The example driverwheel 618 of the pump system 600 illustrated in FIG. 6 is connected tothe rotor shaft 608 such that there is a direct transference of torquefrom the rotor shaft 608 to the driver wheel 618. For example, if thestator 606 generates a first torque to turn the rotor 608 at a firstangular velocity, then the driver wheel 618 also rotates at the firstangular velocity. The example driver wheel 618 is of a shellconfiguration that surrounds the rotor 608 and is fixed to the rotor viaone or more fastening techniques (e.g., bolts, pins, interference fits,adhesives, etc.). In some examples, the driver wheel 618 is additivelymanufactured to include one ore more components of the rotor 608 (e.g.,the permanent magnets). The example driver wheel 618 is radially coupledto a follower wheel 620 (e.g., via gearing or drive belt(s)) to convertthe first torque and the first angular velocity to a second torque and asecond angular velocity that the follower wheel 620 outputs.

The example pump 602 of the pump system 600 illustrated in FIG. 6includes a pump housing 615, a coupling housing 616, the follower wheel620, radial coupling bearing(s) 621, a coupling shaft 622, an impellershaft 624, a magnetic coupling 626, an impeller 628, radial pumpbearing(s) 630, a thrust shaft 632, a thrust bearing 634, a barrier can636, an outer hub 638, an inner hub 640, and a backplate 642. Theexample pump 602 of pump system 600 includes the coupling housing 616 tosupport the radial couplings bearing(s) 621. The example radial couplingbearings 621 support a weight that the coupling shaft 622 and otherparts connected to the coupling shaft 622 produce. In some examples, thecoupling housing 616 is manufactured separately from the motor housing612 and is fixed to the motor housing 612 via bolts, fasteners,adhesives, etc. In some examples, the coupling housing 616 is additivelymanufactured as a portion of the motor housing 612, such that thecoupling housing 616 and the motor housing 612 are the same additivelymanufactured part.

The driver wheel 618 and the follower wheel 620 of the pump system 600illustrated in FIG. 6 are gears (e.g., spur gears, helical gears, doublehelical gears, etc.) radially connected via interlocking gear teeth orpulleys radially connected via a drive belt. In some examples, the gearteeth of the driver wheel 618 generate a force on the gear teeth of thefollower wheel 620. In some examples, the drive belt contacting thedriver wheel 618 generates a tension force that acts on the outersurface of the follower wheel 620. The example force, tension force,and/or the example first torque that the driver wheel 618 generates andthe example first angular velocity at which the driver wheel 618 rotatesare based on the mechanical power output of the motor 604. As describedabove, Equation 1 represents instantaneous mechanical power of thedriver wheel 618 and/or the follower wheel 620 in terms of torque andangular velocity.

Since power is conserved and since the driver wheel 618 and the followerwheel 620 are radially coupled via gearing teeth and/or the drive belt,the instantaneous power of the driver wheel 618 (P₁) is substantiallysimilar to (e.g., within 1% of) the instantaneous power of the followerwheel 620 (P₂). Thus, assuming there is no energy loss (e.g., 100%efficiency) between the driver wheel 618 and the follower wheel 620 dueto heat, vibration, bending, friction, drive belt creep, etc., thetransmission of torque and angular velocity between the driver wheel 618and the follower wheel 620 can be expressed with Equation 2, asdescribed above.

The example driver wheel 618 generates the first torque (τ₁) and theexample follower wheel 620 generates the second torque (τ₂). Asdescribed above, Equation 3 is used to determine the torque output of arotating wheel. The force F that the driver wheel 618 generates is thesubstantially similar (e.g., within 1%) to the force value F that thefollower wheel 620 generates due to Newton's third law with some lossdue to heat, vibration, bending, friction, drive belt creep, etc. Thus,assuming no such loss occurs (e.g., 100% efficiency), Equation 2 andEquation 3 can be combined and reduced into Equation 4, as describedabove, and Equation 4 can be used to determine the angular velocity ofthe follower wheel 620 and the impeller 628. Therefore, if the driverwheel 618 has a greater diameter than the follower wheel 620, theimpeller 628 will rotate at a greater rate than the rotor shaft 608since the impeller 628 is axially coupled to the follower wheel 620 viathe impeller shaft 624, the magnetic coupling 626, etc.

In the illustrated example of FIG. 6 , the driver wheel 618 has a largerdiameter than the follower wheel 620 to make the second angular velocityhigher than the first angular velocity according to Equation 4. Thefollower wheel 620 is fixed (e.g., via one or more bolts) to thecoupling shaft 622. The example coupling shaft 622 is configured suchthat it is axially coupled to the impeller shaft 624 via the magneticcoupling 626. The example impeller shaft 624 is also axially connectedto the impeller 628 via one or more fastenings (e.g., bolts, rods,interference fits, etc.). Since the coupling shaft 622, the magneticcoupling 626, and the impeller shaft 624 connect the follower wheel 620to the impeller 628, the second angular velocity of the follower wheel620 is transferred directly to the impeller 628. In other words, theimpeller 628 and the follower wheel 620 are rotatably interlocked androtate at the same rate.

The example pump 602 of the pump system 600 includes the pump housing615 to frame and/or otherwise support the radial pump bearings 630 andthe thrust bearing 634. In some examples, the pump housing 615 isadditively manufactured to fit a specific configuration and/or geometryof the one or more radial pump bearings 630, the thrust bearing 634,and/or the impeller shaft 624. In some examples, the pump housing 615 isadditively manufactured with the coupling housing 616 and/or the motorhousing 612 such that the pump housing 615 is the same part as thecoupling housing 616 and/or the motor housing 612. The example pumphousing 615 as illustrated in FIG. 6 is fabricated (e.g., additivelymanufactured) separately from the coupling housing 616 and the motorhousing 612. The example pump housing 615 as illustrated in FIG. 6 isfastened to the coupling housing 616 and the motor housing 612 via oneor more bolts. In some examples, the pump housing 615 is fastened to thecoupling housing 616 and the motor housing 612 via one or more bolts,dowels, interference fits, and/or adhesives.

The example pump 602 of the pump system 600 includes the radial pumpbearing(s) 630 to support a radial load that the impeller shaft 624produces. In some examples, the radial pump bearing(s) 630 are rollingelement bearings similar to the radial motor bearing(s) 610 and/or theradial coupling bearing(s) 621. In the example pump system 600illustrated in FIG. 6 , the radial pump bearing(s) 630 are foilbearings. In some examples, the radial pump bearing(s) 630 include aspring-loaded foil lining inside of a bearing sleeve. The examplespring-loaded foil lining supports the weight of the impeller shaft 624as the impeller shaft 624 begins to rotate. As the second angularvelocity of the impeller shaft 624 increases, the air pressure betweenthe impeller shaft 624 and the spring-loaded foil lining increases. Asthe second angular velocity continues to increase, the air pressure alsoincreases to the point where the air pressure pushes the spring-loadedfoil lining perpendicularly outward from the axis of rotation. Theexample air gap that forms in the radial pump bearing 630 between theimpeller shaft 624 and a sleeve of the radial pump bearing 630 is whatthen supports the weight of the impeller shaft 624.

The example radial pump bearing(s) 630 do not use fluid lubrication(e.g., oil lubricants) that can contaminate the fluid. However, theexample radial pump bearing(s) 630 (e.g., foil bearings) cannot supportaxial loads that the follower wheel 620, the coupling shaft 622, and/orthe impeller shaft 624 generate. The example pump housing 615 and thebackplate 642 illustrated in FIG. 6 frame the thrust bearing 634 suchthat thrust bearing 634 supports the thrust load that the impeller shaft624 generates. The example thrust shaft(s) 632 are fixed to the impellershaft 624 and/or are otherwise rigidly extending from the impeller shaft624 perpendicular to the axis of rotation of the impeller shaft 624. Asthe impeller shaft 624 rotates and transfers an axial and/or thrust loadto the thrust shaft(s) 632, the thrust bearing 634 counteracts the axialload from the thrust shaft(s) 632 while allowing the impeller shaft 624to rotate with limited (e.g., less than 1%) energy loss. While twothrust shafts 632 and one thrust bearing 634 are illustrated in FIG. 5 ,there can be two or more thrust shafts 632 and/or one or more thrustbearings 634 in the pump system 600. In some examples, the thrustbearing 634 can be a thrust ball bearing, a cylindrical thrust rollerbearing, a tapered roller thrust bearing, a spherical roller thrustbearing, a magnetic bearing, etc.

The example pump 602 of the pump system 600 illustrated in FIG. 6includes the magnetic coupling 626 to connect the coupling shaft 622 andthe impeller shaft 624. The example magnetic coupling 626 includes theouter hub 638 and the inner hub 640 both including permanent magnetsthat alternate in polarity around the axis of rotation. The exampleinner hub 640 is the male component of the magnetic coupling 626 andfits within the outer hub 638 (e.g., the female component). The magneticforces of the permanent magnets cause the coupling shaft 622 to transfertorque directly to the impeller shaft 624 such that the impeller shaft624 and the impeller 628 rotate at the same second angular velocity asthe follower wheel 620. The coupling shaft 622 is magnetically coupledto the impeller shaft 624 such that a gap exists between the male andfemale components. The example barrier can 636 (e.g., barrier can 452)is designed to fit within the gap without physically and/or magneticallyinterfering with the magnetic coupling 626.

The example barrier can 636 is fixed in the magnetic coupling 626, thecoupling housing 616, and/or the pump housing 615 to hermetically sealthe follower wheel 620, the coupling shaft 622, and the motor 604 fromthe fluid. The example barrier can 636 also hermetically seals exampleoil(s) that the radial motor bearing(s) 610, the driver wheel 618, thefollower wheel 620, and/or the motor 604 use as lubricant fromcontaminating the fluid. In some examples, the barrier can 636 is of thesame structure, materials, design, etc. as the barrier can 452 of FIG. 4. In some examples, the barrier can 636 of FIG. 6 is also fixed to thecoupling housing 616 and/or the motor housing 612 in the same manner asthe barrier can 452 of FIG. 4 , such as via a flange, a barrier canretainer ring, and/or bolts.

In some examples, the barrier can 636 includes an inner shell, a middlelayer, and an outer layer. In some examples, the inner layer and outerlayer are composed of various combinations of ceramic, polymer, orcomposite, and the middle layer is composed of metal electroformed overthe inner layer mandrel. Some further examples of the barrier can 636including materials, structure, design, etc., are described in greaterdetail in other sections of this document.

A radially coupled pump system 600 is disclosed herein. The examplesdisclosed herein include an electric motor 604 with a stator 606 that ismounted inside of a cylindrical rotor shaft 608 that rotates around theoutside of the stator 606. The examples disclosed herein include adriver wheel 618 that surrounds and is fixed to the rotor 608 such thatthe rotor 608 transfers a first torque output of the rotor 608 directlyto the driver wheel 618. The examples disclosed herein include that thedriver wheel 618 is radially coupled to a follower wheel 620 via gearingor a drive belt. The examples disclosed herein further include that thefollower wheel 620 is axially connected to an impeller shaft 624 via amagnetic coupling 626 to drive a pump 602. The examples disclosed hereinfurther include that the driver wheel 618 has a first diameter and thefollower wheel 620 has a second diameter that is smaller than the firstdiameter. Thus, examples disclosed herein further include that thedriver wheel 618 rotates at a first angular velocity and that thefollower wheel 620 rotates at a second angular velocity, wherein thesecond angular velocity is greater than the first angular velocity.Examples disclosed herein allow the motor 604 to be mounted above orbelow portions of the pump 602 such that the pump system 600 saves spacein the axial direction relative to pump systems that are axially coupledand aligned (e.g., pump 400 of FIG. 4 ). Examples disclosed hereinoperate the electric motor 604 more efficiently, increase the lifetimeof the motor 604, increase the power density of the pump system 600, andincrease the maximum angular velocity of the impeller 628 relative tothose of the example pump 400 of FIG. 4 because the electric motor 604can output less mechanical power than the motor 410 to achieve the sameangular velocity as the impeller 406.

FIG. 7 illustrates a cross-sectional view of a radially coupled pumpsystem 700 for pressurizing fluid (e.g., a heat exchange fluid such as asupercritical fluid (e.g., sCO₂, etc.)) in a system (e.g., thermalmanagement system 200 of FIG. 3 ). As shown in FIG. 7 , the radiallycoupled pump system 700 (“pump system 700”) includes a pump 702 and anelectric motor 704. In some examples, the pump system 700 is used topump sCO₂ through a thermal management system on an aircraft (e.g.,aircraft 10 of FIG. 1 ) and/or a gas turbine engine (e.g., gas turbineengine 100 of FIG. 2 ). In some examples, the electric motor 704 of thepump system 700 includes a stator 706, a rotor 708, radial motorbearing(s) 710, a motor housing 712, a cooling jacket 714, a couplinghousing 716, a coupling shaft 718, a coupling bolt 719, a magneticcoupling 720, a driver wheel 722, a driver wheel shaft 724, radialdriver wheel shaft bearings 726, a barrier can 728, an inner hub 730,and an outer hub 732.

The example electric motor 704 of pump system 700 illustrated in FIG. 7includes the stator 706 and the rotor 708. In some examples, the stator706 includes field magnets (e.g., electromagnets or permanent magnets)that generate magnetic field(s) based on an electric current (e.g.,direct current or alternating current) passing through various theelectromagnets of the stator 706. The example stator 706 generates afirst set of magnetic fields that apply a force (e.g., Lorentz force) ona second set of magnetic fields that the rotor 708 generates. Theexample rotor 708 generates the second set of magnetic fields viapermanent magnets or electromagnets. Since the stator 706 is stationaryand fixed in place, the force causes the example rotor 708 to rotate andto produce a torque.

The example electric motor 704 of pump system 700 includes radial motorbearings 710 that support a weight of the rotor shaft 708 and keep therotor 708 in radial and/or axial alignment. The example radial motorbearings 710 support a radial load (e.g., weight) and a thrust load ofthe rotor 708. In some examples, the radial motor bearings 710 arerolling element bearings, such as angular contact ball bearings, hybridceramic bearings, taper roller bearings, deep groove single ballbearings, duplex ball bearings, spherical bearings, etc. In someexamples, the radial motor bearings 710 use liquid lubricant(s) (e.g.,grease, oil, etc.) to reduce friction and wear in rotating elements ofthe radial motor bearings 710. In some examples, the radial motorbearings 710 use a solid lubricant (e.g., silver coating) to reducefriction and wear of the rotating elements of the radial motor bearings710. In some examples, the radial motor bearings 710 are foil bearingsthat use pressurized air to create a non-contact barrier between therotor shaft and a sleeve of the radial motor bearings 710 atsufficiently high rotational speeds. Although the electric motor 704illustrated in FIG. 7 includes two radial motor bearings 710, one ormore radial motor bearings 710 can be used in the electric motor 704.

The example electric motor 704 of pump system 700 includes the motorhousing 712 to frame and/or otherwise support the stator 706, radialmotor bearing(s) 710, etc. In some examples, the motor housing 712 isadditively manufactured (e.g., via direct metal laser sintering (DMLS),three-dimensional printing, etc.) to accommodate custom geometries andconfigurations of the stator 706, the radial motor bearing(s) 710, thecooling jacket 714, etc.

Since the example stator 706 uses electromagnets to generate Eddycurrents, the example pump system 700 illustrated in FIG. 7 includes thecooling jacket 714 to dissipate heat that the stator 706 generatesduring operation. In some examples, the cooling jacket 714 ismechanically fixed to the motor housing 712 and includes cooling fins,vents, channels, etc. to transfer heat from the stator 706 to air,water, gas coolant, liquid coolant, etc. The example motor housing 712illustrated in FIG. 7 is an additively manufactured structure thatincludes the cooling jacket 714 as an additively manufactured portion ofthe motor housing 712 such that the cooling jacket 714 and the motorhousing 712 are the same additively manufactured part. The examplecooling jacket 714 illustrated in FIG. 7 is manufactured in conjunctionwith the motor housing 712 to surround the stator 706 and transfer heatfrom the stator 706 to air, water, gas coolant, liquid coolant, etc. viacooling fins, vents, channels, etc.

The example electric motor 704 of pump system 700 includes the couplinghousing 716 to support the driver wheel shaft bearing(s) 726, thebarrier can 728, etc. In the illustrated example of FIG. 7 , thecoupling housing 716 is manufactured separately from the motor housing712 and is fixed to the motor housing 712 via one or more bolts. In someexamples, the coupling housing 716 is manufactured separately (viaadditive manufacturing or subtractive manufacturing) from the motorhousing 712 and is fixed to the motor housing 712 via bolts, dowels,interference fits, and/or adhesives. In some examples, the couplinghousing 716 is additively manufactured as a portion of the motor housing712, such that the coupling housing 716 and the motor housing 712 arethe same additively manufactured part.

The example electric motor 704 of the pump system 700 includes thedriver wheel 722 coupled to the rotor shaft 708. The example driverwheel 722 of the pump system 700 illustrated in FIG. 7 is connected tothe rotor shaft 708 via the coupling shaft 718 and the magnetic coupling720 such that there is a direct transference of torque from the rotorshaft 708 to the driver wheel 722. For example, if the stator 706generates a first torque to turn the rotor 708 at a first angularvelocity, then the driver wheel 722 also rotates at the first angularvelocity. The example driver wheel 722 is radially coupled to a followerwheel 734 to convert the first torque and the first angular velocity toa second torque and a second angular velocity that the follower wheel734 outputs.

The example motor 704 of the pump system 700 illustrated in FIG. 7includes the magnetic coupling 720 to connect the coupling shaft 718 andthe driver wheel shaft 724. The example coupling shaft 718 is rigidlyconnected to the rotor shaft 708 via the coupling bolt 719 aligned withaxes of rotation of the rotor shaft 708 and the coupling shaft 718. Theexample magnetic coupling 720 includes the outer hub 732 and the innerhub 730 both including permanent magnets that alternate in polarityaround the axis of rotation. The example inner hub 730 is the malecomponent of the magnetic coupling 720 and fits within the outer hub 732(e.g., the female component). The magnetic forces of the permanentmagnets cause the coupling shaft 718 to transfer torque directly to thedriver wheel shaft 724 such that the driver wheel shaft 724 and thedriver wheel 722 rotate at the same second angular velocity as the rotorshaft 708. The coupling shaft 718 is magnetically coupled to the driverwheel shaft 724 such that a gap exists between the male and femalecomponents. The example barrier can 728 (e.g., barrier can 452) isdesigned to fit within the gap without physically and/or magneticallyinterfering with the magnetic coupling 720.

The example barrier can 728 is fixed in the magnetic coupling 720 and/orthe coupling housing 716 to hermetically seal the motor 504 from thefluid. The example barrier can 728 also hermetically seal example oil(s)that the radial motor bearing(s) 710, the rotor shaft 708, and/or themotor 704 use as lubricant from contaminating the fluid. In someexamples, the barrier can 728 is of the same structure, materials,design, etc. as the barrier can 452 of FIG. 4 . In some examples, thebarrier can 728 of FIG. 7 is also fixed to the coupling housing 716 inthe same manner as the barrier can 452 of FIG. 4 , such as via a flange,a barrier can retainer ring, and/or bolts.

In some examples, the barrier can 728 includes an inner shell, a middlelayer, and an outer layer. In some examples, the inner layer and outerlayer are composed of various combinations of ceramic, polymer, orcomposite, and the middle layer is composed of metal electroformed overthe inner layer mandrel. Some further examples of the barrier can 728including materials, structure, design, etc. are described in greaterdetail in other sections of this document.

The example motor 704 of the pump system 700 includes the radial driverwheel shaft bearings 726 to support a radial load that the driver wheelshaft 724 produces. In some examples, the radial driver wheel shaftbearings 726 are rolling element bearings similar to the radial motorbearing(s) 710. In the example pump system 700 illustrated in FIG. 7 ,the radial driver wheel shaft bearings 726 are foil bearings. In someexamples, the radial driver wheel shaft bearings 726 include aspring-loaded foil lining inside of a bearing sleeve. The examplespring-loaded foil lining supports the weight of the driver wheel shaft724 as the driver wheel shaft 724 begins to rotate. As the first angularvelocity of the driver wheel shaft 724, the coupling shaft 718, and therotor shaft 708 increases, the air pressure between the driver wheelshaft 724 and the spring-loaded foil lining increases. As the firstangular velocity continues to increase, the air pressure also increasesto the point where the air pressure pushes the spring-loaded foil liningoutward from the axis of rotation. The example air gap that forms in theradial driver wheel shaft bearings 726 between the driver wheel shaft724 and a sleeve of the radial driver wheel shaft bearings 726 is whatthen supports the weight of the driver wheel shaft 724.

The example radial driver wheel shaft bearings 726 do not use fluidlubrication (e.g., oil lubricants) that can contaminate the fluid.However, the example radial driver wheel shaft bearings 726 (e.g., foilbearings) cannot support an axial load that the driver wheel 722 and/orthe driver wheel shaft 724 generate. In the illustrated pump system 700of FIG. 7 , the magnetic coupling 720 supports the axial load (e.g.,thrust load). In some examples, the driver wheel shaft 724 can includeone or more thrust shafts fixed and/or otherwise radially extendingoutward from the driver wheel shaft 724 perpendicular to an axis ofrotation of the driver wheel shaft 724. In some examples, the couplinghousing 716 and/or a pump housing 735 frame one or more thrust bearingsthat support the one or more example thrust shafts that can be includedwith the driver wheel shaft 724.

The example pump 702 of the pump system 700 illustrated in FIG. 7includes the follower wheel 734, the pump housing 735, an impeller shaft736, an impeller 738, radial pump bearing(s) 740, thrust shaft(s) 742,and a thrust bearing 744. The driver wheel 722 and the follower wheel734 of the pump system 700 illustrated in FIG. 7 can be gears (e.g.,spur gears, helical gears, double helical gears, etc.) radiallyconnected via interlocking gear teeth or pulleys radially connected viaa drive belt. In some examples, the gear teeth of the driver wheel 722generate a force on the gear teeth of the follower wheel 734. In someexamples, the drive belt contacting the driver wheel 722 generates atension force that acts on the outer surface of the follower wheel 734.The example force, tension force, and/or the example first torque thatthe driver wheel 722 generates and the example first angular velocity atwhich the driver wheel 722 rotates are based on the mechanical poweroutput of the motor 704. As described above, Equation 1 representsinstantaneous mechanical power of the driver wheel 722 and/or thefollower wheel 734 in terms of torque and angular velocity.

Since power is conserved and since the driver wheel 722 and the followerwheel 734 are radially coupled via gearing teeth and/or the drive belt,the instantaneous power of the driver wheel 722 (P₁) is substantiallysimilar to (e.g., within 1% of) the instantaneous power of the followerwheel 734 (P₂). Thus, assuming there is no energy loss (e.g., 100%efficiency) between the driver wheel 722 and the follower wheel 734 dueto heat, vibration, bending, friction, drive belt creep, etc., thetransmission of torque and angular velocity between the driver wheel 722and the follower wheel 734 can be expressed with Equation 2, asdescribed above.

The example driver wheel 722 generates the first torque (τ1) and theexample follower wheel 734 generates the second torque (τ₂). Asdescribed above, Equation 3 is used to determine the torque output of arotating wheel. The force F that the driver wheel 722 generates is thesubstantially similar (e.g., within 1%) to the force value F that thefollower wheel 734 generates due to Newton's third law with some lossdue to heat, vibration, bending, friction, drive belt creep, etc. Thus,assuming no such loss occurs (e.g., 100% efficiency), Equation 2 andEquation 3 can be combined and reduced into Equation 4, as describedabove, and Equation 4 can be used to determine the angular velocity ofthe follower wheel 734 and the impeller 738. Therefore, if the driverwheel 722 has a greater diameter than the follower wheel 734, theimpeller 738 will rotate at a greater rate than the rotor shaft 708since the impeller 738 is axially coupled to the follower wheel 734 viathe impeller shaft 736.

In the illustrated example of FIG. 7 , the driver wheel 722 has a largerdiameter than the follower wheel 734 to make the second angular velocityhigher than the first angular velocity according to Equation 4. Thefollower wheel 734 is fixed (e.g., via one or more bolts, welds,adhesives, interference fits, etc.) to the impeller shaft 736. Theexample impeller shaft 736 is axially connected to the impeller 738 viaone or more fastenings (e.g., bolts, rods, interference fits, etc.).Since the impeller shaft 736 connects the follower wheel 734 to theimpeller 738, the second angular velocity of the follower wheel 734 istransferred directly to the impeller 738. In other words, the impeller738 and the follower wheel 734 are rotatably interlocked and rotate atthe same rate.

The example pump 702 of the pump system 700 includes the radial pumpbearing(s) 740 to support a radial load that the impeller shaft 736produces. In some examples, the radial pump bearing(s) 740 are rollingelement bearings similar to the radial motor bearing(s) 710. In theexample pump system 700 illustrated in FIG. 7 , the radial pumpbearing(s) 740 are foil bearings. In some examples, the radial pumpbearing(s) 740 include a spring-loaded foil lining inside of a bearingsleeve. The example spring-loaded foil lining supports the weight of theimpeller shaft 736 as the impeller shaft 736 begins to rotate. As thesecond angular velocity of the impeller shaft 736 increases, the airpressure between the impeller shaft 736 and the spring-loaded foillining increases. As the second angular velocity continues to increase,the air pressure also increases to the point where the air pressurepushes the spring-loaded foil lining outward from the axis of rotation.The example air gap that forms in the radial pump bearing 740 betweenthe impeller shaft 736 and a sleeve of the radial pump bearing 740 iswhat then supports the weight of the impeller shaft 736.

The example radial pump bearing(s) 740 do not use fluid lubrication(e.g., oil lubricants) that can contaminate the fluid. However, theexample radial pump bearing(s) 740 (e.g., foil bearings) cannot supportaxial loads that the follower wheel 734 and/or the impeller shaft 736generate. The example pump 702 of the pump system 700 includes thrustshaft(s) 742 to interface with the thrust bearing 744. The example pumphousing 735 and the coupling housing 716 illustrated in FIG. 7 frame thethrust bearing 744 such that thrust bearing 744 supports the thrust loadthat the thrust shaft(s) 742 generates. The example thrust shaft(s) 742are fixed to the impeller shaft 736 and/or are otherwise rigidlyextending from the impeller shaft 736 perpendicular to the axis ofrotation of the impeller shaft 736. As the impeller shaft 736 rotatesand transfers an axial and/or thrust load to the thrust shaft(s) 742,the thrust bearing 744 counteracts the axial load from the thrustshaft(s) 742 while allowing the impeller shaft 736 to rotate withlimited (e.g., less than 1%) energy loss. While two thrust shafts 742and one thrust bearing 744 are illustrated in FIG. 7 , there can be twoor more thrust shafts 742 and/or one or more thrust bearings 744 in thepump system 700. In some examples, the thrust bearing 744 can be athrust ball bearing, a cylindrical thrust roller bearing, a taperedroller thrust bearing, a spherical roller thrust bearing, a magneticbearing, etc.

A radially coupled pump system 700 is disclosed herein. The examplesdisclosed herein include an electric motor 704 to drive a pump 702 via adriver wheel 722 axially connected to a motor shaft 708 via a magneticcoupling 720. The examples disclosed herein further include a followerwheel 734 radially coupled to the driver wheel 722 via gearing or adrive belt. The examples disclosed herein further include that thefollower wheel 734 is axially connected to an impeller shaft 736. Theexamples disclosed herein further include that the driver wheel 722 hasa first diameter and the follower wheel 734 has a second diameter thatis smaller than the first diameter. Thus, the examples disclosed hereinfurther include that the driver wheel 722 rotates at a first angularvelocity and that the follower wheel 734 rotates at a second angularvelocity that is greater than the first angular velocity. The examplesdisclosed herein allow the motor 704 to be mounted above or belowportions of the pump 702 such that the pump system 700 saves space inthe axial direction relative to pump systems that are axially coupledand aligned (e.g., pump 400 of FIG. 4 ). The examples disclosed hereinoperate the electric motor 704 more efficiently, increase the lifetimeof the motor 704, increase the power density of the pump system 700, andincrease the maximum angular velocity of the impeller 738 relative tothose of the example pump 400 of FIG. 4 because the electric motor 704can output less mechanical power than the motor 410 to achieve the sameangular velocity as the impeller 406.

FIG. 8 is a flow diagram illustrating an example process or operation800 that the pump systems 500 (FIG. 5 ), 600 (FIG. 6 ), 700 (FIG. 7 )may follow as disclosed herein to pressurize a fluid (e.g., a heatexchange fluid such as a supercritical fluid (e.g., supercritical carbondioxide (sCO₂), etc.)) in a thermal management system transport bus(e.g., the thermal transport bus 202 of FIG. 2 ). While the operation800 is described with primary reference to pumping the fluid with thepump systems 500, 600, 700 of FIGS. 5-7 within a thermal managementsystem transport bus, the operation 800 can be used to pump the fluidwithin any other closed loop transport bus.

At block 802, an electric motor 504, 604, 704 generates a first torqueand a first velocity on a rotor shaft 508, 608, 708. For example, anelectrical current is supplied to electromagnets of a stator 506, 606,706 to induce magnetic fields that are perpendicular to the axis ofrotation of the rotor 508, 608, 708. The electromagnets of the stator506, 606, 706 are charged sequentially with varying flow directions ofelectrical current such that the varying polarities of magnetic fieldsare activated to attract permanent magnets in the rotor 508, 608, 708.The magnetic forces between the electromagnets in the stator 506, 606,706 and the permanent magnets in the rotor 508, 608, 708 provide thefirst torque and the first angular velocity to the rotor shaft 508, 608,708.

At block 804, the process or operation 800 proceeds to either block 806or block 808 depending on the location and/or configuration of amagnetic coupling 526, 626, 720 in the pump system 500, 600, 700. If therotor shaft 508, 608, 708 and a driver wheel 518, 618, 722 are coupledvia the magnetic coupling 526, 626, 720, then the process or operation800 proceeds to block 806 where the rotor 508, 608, 708 directlytransfers the first torque and the first angular velocity to the driverwheel 518, 618, 722 via the magnetic coupling 526, 626, 720. If therotor shaft 508, 608, 708 and the driver wheel 518, 618, 722 are notcoupled via the magnetic coupling 526, 626, 720, then the process oroperation 800 proceeds to block 808 where the rotor 508, 608, 708directly transfers the first torque and the first angular velocity tothe driver wheel 518, 618, 722 via a first mechanical connection (e.g.,bolt(s), dowel(s), adhesive(s), interference fit, etc.).

At block 810, the process or operation 800 proceeds to either block 812or block 814 depending on the design, structure, and/or configuration ofthe driver wheel 518, 618, 722 and a follower wheel 520, 620, 734. Ifthe driver wheel 518, 618, 722 and the follower wheel 520, 620, 734 areboth gears that are radially coupled via interlocking gear teeth, thenthen the process or operation 800 proceeds to block 812 at which thefirst torque and the first angular velocity of the driver wheel 518,618, 722 are converted to a second torque and a second angular velocityof the follower wheel 520, 620, 734 via the interlocking gear teeth. Oneor more gear teeth of the driver wheel 518, 618, 722 exert a force onone or more gear teeth of the follower wheel 520, 620, 734. The forcetransfers to the follower wheel 520, 620, 734 and creates the secondtorque and the second angular velocity.

At block 814, if the driver wheel 518, 618, 722 and the follower wheel520, 620, 734 are not both gears that are radially coupled viainterlocking gear teeth, then the first torque and the first angularvelocity of the driver wheel 518, 618, 722 are converted to the secondtorque and the second angular velocity of the follower wheel 520, 620,734 via a drive belt connection between the driver wheel 518, 618, 722and the follower wheel 520, 620, 734. The drive belt is designed and/orassembled to have a non-slip contact with the driver wheel 518, 618, 722and the follower wheel 520, 620, 734. The driver wheel 518, 618, 722exerts a tension force on the drive belt, and the tension forcetransfers to an area on the follower wheel 520, 620, 734 where the drivebelt contacts the follower wheel 520, 620, 734. The transference of thetension force creates the second torque and the second angular velocityof the follower wheel 520, 620, 734.

At block 816, the process or operation 800 proceeds to either block 818or block 820 depending on the location and configuration of the magneticcoupling 526, 626, 720 in the pump system 500, 600, 700. If the followerwheel 520, 620, 734 and an impeller shaft 524, 624, 736 are coupled viathe magnetic coupling 526, 626, 720, then the process or operation 800proceeds to block 818 where the follower wheel 520, 620, 734 directlytransfers the second torque and the second angular velocity to theimpeller shaft 524, 624, 736 via the magnetic coupling 526, 626, 720and/or a coupling shaft 522, 622, 718. If the follower wheel 520, 620,734 and the impeller shaft 524, 624, 736 are not coupled via themagnetic coupling 526, 626, 720, then the process or operation 800proceeds to block 820 where the follower wheel 520, 620, 734 directlytransfers the second torque and the second angular velocity to theimpeller shaft 524, 624, 736 via a second mechanical connection (e.g.,bolt(s), dowel(s), adhesive(s), interference fit, etc.).

At block 822, an impeller 528, 628, 738 connected to the impeller shaft524, 624, 736 generates hydrodynamic energy of the fluid based on arotational kinetic energy of the impeller 528, 628, 738. Since theimpeller 528, 628, 738 is axially coupled and/or connected to theimpeller shaft 524, 624, 736, the impeller 528, 628, 738 also rotates atthe second angular velocity. The rotational kinetic energy of theimpeller 528, 628, 738 is based on the second angular velocity and amoment of inertia of the impeller 528, 628, 738. The rotational energyis converted into hydrodynamic energy based on the law of conservationof energy and a design of the impeller 528, 628, 738.

In some examples, the pump systems 500, 600, 700 include means forrotating. For example, the means for rotating may be implemented by themotors 504, 604, 704, the stators 506, 606, 706, and/or the rotor shafts508, 608, 708 of FIGS. 5, 6 , and/or 7. In some examples, the means forrotating may include an electric motor, such as a DC motor, an AC motor,a brushed DC motor, a brushless DC motor, etc.

In some examples, the pump systems 500, 600, 700 include means foraccelerating. For example, the means for accelerating may be implementedby the impellers 528, 628, 738 and/or the impeller shafts 524, 624, 736of FIGS. 5-8 . In some examples, the means for increasing may include anelectric motor, an impeller shaft, and/or an impeller.

In some examples, the pump systems 500, 600, 700 include means forconverting. For example, the means for converting may be implemented bythe driver wheels 518, 618, 722 and/or the follower wheels 520, 620, 734of FIGS. 5-7 . In some examples, the means for converting may includegears in contact via interlocking gear teeth or pulley wheels in contactwith a drive belt.

In some examples, the pump systems 500, 600, 700 include means forconnecting. For example, the means for connecting may be implemented bythe magnetic couplings 526, 626, 720 of FIGS. 5-7 . In some examples,the means for connecting may include a magnetic coupling, an inner hub,an outer hub, a coupling shaft, and/or permanent magnets.

In some examples, the pump systems 500, 600, 700 include means forframing. For example, the means for framing may be implemented by themotor housings 512, 612, 712, the coupling housings 516, 616, 716,and/or the pump housings 615, 735 of FIGS. 5, 6 , and/or 7. In someexamples, the means for framing may include a housing, shell, supportstructure, etc. manufactured via additive manufacturing (e.g., binderjetting, directed energy deposition, powder bed infusion, direct metallaser sintering etc.).

Integrated Bearing Systems for Dynamically Supporting Shafts in PumpSystems

The operations of some example fluid pump systems and centrifugal fluidpump systems have an electric motor (e.g., motor 410) connected axiallyto an impeller (e.g., impeller 406) via an impeller shaft (e.g.,impeller shaft 466) as described in reference to FIG. 4 above. Theexample rotor shaft 438 illustrated in FIG. 4 is connected to theexample impeller shaft 466 via a first magnetic coupling 450 and asecond magnetic coupling 460. In some examples, a rotor shaft isconnected directly to the impeller in a pump system without a magneticcoupling to connect the rotor shaft and an impeller shaft. In someexamples, a foil bearing is used to support a radial load that the rotorshaft generates during operation of the pump system. A foil bearing is aform of air bearing that uses a spring-loaded foil between a shaft and ajournal lining to support the shaft at low startup speeds. Once theshaft is rotating at a high enough rate (depending on the architectureof the foil bearing) a working fluid (e.g., air, nitrogen, argon, etc.)is pulled into the foil bearing due to the viscosity effects of theworking fluid. Thus, the working fluid pressure increases in the foilbearing, pushes the foil outward from the shaft, and supports the radialload that the shaft generates creating a frictionless bearing with noliquid lubricants. Since the foil bearing does not use liquidlubricants, a hermetic sealing (e.g., a magnetic coupling) may not beused to prevent lubricants from contaminating a fluid (e.g., heatexchange fluid such as a supercritical fluid (e.g., sCO₂, etc.)) thatthe pump system pressurizes.

In some examples, the foil bearing used to support the radial load thatthe rotor shaft produces experiences wear during the start-up andstopping of the pump system. More specifically, the spring-loaded foilthat supports the weight of the rotor shaft at lower speeds (start-upand stopping rotational speeds) experiences damage over time due tofrictional erosion. In the examples disclosed herein, integrated bearingsystems include a foil bearing, a rolling element bearing, and adisengaging-type sprag clutch to support a rotor shaft in a pump system.The example sprag clutch engages the rolling-element bearing prior tooperation of the pump system and at lower operating speeds of the pumpsystem such that the rolling-element bearing supports the weight (e.g.,the total weight and/or a majority of the weight) of the rotor shaftduring start-up and stopping speeds of the pump system. In the examplesdisclosed herein, when the pump system reaches a first operational speedrange (e.g., a foil bearing lift off speed (e.g., 10 to 50 meters persecond (m/s) tangential velocity of the foil bearing)), the sprag clutchdisengages from the rolling element bearing, and the foil bearingsupports the weight of the rotor shaft. Thus, the examples disclosedherein reduce the radial load that the foil bearing supports duringstart-up and stopping of the pump system, reduce the wear of the foilbearings due to less frictional erosion, and increase the lifespan(e.g., usable life) of the foil bearings.

For the figures disclosed herein, identical numerals indicate the sameelements throughout the figures. FIG. 9 illustrates a cross-sectionalview of a pump system 900 for pressurizing fluid (e.g., a heat exchangefluid such as a supercritical fluid (e.g., sCO₂, etc.)) in a system(e.g., thermal management system 200 of FIG. 3 ). In some examples, thepump system A100 is used to pump sCO₂ through a thermal managementsystem on an aircraft (e.g., aircraft 10 of FIG. 1 ) and/or a gasturbine engine (e.g., gas turbine engine 100 of FIG. 2 ). As shown inFIG. 9 , the pump system 900 includes an impeller 902, a rotor shaft904, a rotor 905, a stator 906, a thrust bearing 908, radial shafts 909,a first integrated bearing system 910, a first sprag clutch 912, a firstbearing housing 913, a first rolling-element bearing 914, a first foilbearing 916, a second integrated bearing system 918, a second spragclutch 920, a second bearing housing 921, a second rolling-elementbearing 922, and a second foil bearing 924.

The example pump system 900 illustrated in FIG. 9 includes the impeller902 to pressurize the fluid (e.g., sCO₂) in the system (e.g., thethermal management system 200 of FIG. 3 ). The example impeller 902 is acomponent of the pump system 900 that is connected to the rotor shaft904 and rotates at a same rotational speed as the rotor shaft 904. Insome examples, the impeller 902 is same as or similar to impellers usedin centrifugal pumps and includes vanes and/or blades to deflect flow ofthe incoming fluid radially outward into outlet flowlines. The exampleimpeller 902 converts mechanical power of the motor (e.g., the rotorshaft 904 and the stator 906) into hydrodynamic power of the fluid flow.

The example pump system 900 illustrated in FIG. 9 includes the stator906 to apply a torque on the rotor 905, which is coupled to the rotorshaft 904. Since the example rotor 905 is connected to the rotor shaft904 (e.g., via bolts, adhesives, interference fit, etc.), the stator 906causes the rotor shaft 904 to rotate while the stator 906 remainsstationary. The example stator 906, the example rotor 905, and theexample rotor shaft 904 are included as parts of an electric motor thatis familiar to those with skill in the art. In some examples, the stator906 includes field magnets (e.g., electromagnets or permanent magnets)that generate magnetic field(s) based on an electric current (e.g.,direct current or alternating current) passing through various theelectromagnets of the stator 906. The example stator 906 generates afirst set of magnetic fields that apply a force (e.g., Lorentz force) ona second set of magnetic fields that the rotor 905 generates. Theexample rotor 905 generates the second set of magnetic fields viapermanent magnets or electromagnets. Since the example stator 906 isstationary and fixed in place, the force causes the example rotor 905 torotate and to produce a torque. Since the example rotor shaft 904 isconnected to the example rotor 905, the rotor shaft 904 produces thesame torque and rotates at a same angular velocity as the rotor 905.

The example pump system 900 illustrated in FIG. 9 includes the thrustbearing 908 to support the thrust load (axial load) that the rotor shaft904 generates during operation. The example thrust bearing 908illustrated in FIG. 9 is a foil bearing that includes a spring-loadedfoil and a journal lining, similar to the foil bearing architecturedescribed above. The example rotor shaft 904 is connected to two or moreradial shafts 909 that are positioned perpendicular to the axis ofrotation of the rotor shaft 904. In some examples, the radial shafts 909are connected to the rotor shaft via bolts, adhesives, interferencefits, etc.

The example pump system 900 illustrated in FIG. 9 includes two radialshafts 909, however, more radial shafts 909 may be connected to therotor shaft 904. In some examples, the thrust bearing 908 includes aninner lining that interfaces with the radial shafts 909 and thespring-loaded foil. In some examples, the radial shafts 909 is a diskthat is connected to the rotor shaft 904 and interacts directly with thespring-loaded foil of the thrust bearing 908.

The example pump system 900 of FIG. 9 includes the first integratedbearing system 910 to support the radial loads of the rotor shaft 904during operation of the pump system 900. The example first integratedbearing system 910 includes the first sprag clutch 912, the bearinghousing 913, the first rolling-element bearing 914, and the first foilbearing 916. The example pump system 900 of FIG. 9 also includes thesecond integrated bearing system 918 to similarly support the radialloads of the rotor shaft 904. The second integrated bearing system 918includes the second sprag clutch 920, the second rolling-element bearing922, and the second foil bearing 924. In some examples, the pump system900 includes one integrated bearing system. In some examples, the pumpsystem 900 includes one or more integrated bearing systems. The examplefirst integrated bearing system 910 and the example second integratedbearing system 918 of the example pump system 900 illustrated in FIG. 9are substantially similar. Thus, references and descriptions regardingthe first integrated bearing system 910 (“bearing system 910”), thefirst sprag clutch 912 (“sprag clutch 912”), the first bearing housing913 (“bearing housing 913”), the first rolling-element bearing 914(“rolling-element bearing 914”), and the first foil bearing 916 (“foilbearing 916”) can also be applied to the second integrated bearingsystem 918, the second sprag clutch 920, the second bearing housing 921,the second rolling-element bearing 922, and the second foil bearing 924,respectively.

The example pump system 900 illustrated in FIG. 9 includes the spragclutch 912 to engage and disengage the rolling-element bearing 914 andthe foil bearing 916 from one another during operation of the pumpsystem 900. The example sprag clutch 912 is a disengaging-type spragclutch that resembles a rolling-element bearing but includesnon-revolving asymmetric sprag elements instead of revolving symmetriccylinders, spheres, etc. The example sprag clutch 912 includes an innerrace and an outer race between which the sprag elements fit in place.The example sprag clutch 912 also includes a spring ribbon to produce apre-loaded spring force on the sprag elements to engage the sprag clutchwith the inner race and the outer race during non-operation. Due to theasymmetric figure-eight shaped geometry of the sprag elements, when thesprag elements rotate and wedge between the outer race and the innerrace, the fiction force that occurs between the components of the spragclutch 912 cause the inner race to rotate at the same angular velocityas the outer race. When the example sprag clutch 912, inner race, andouter race rotate at a first operational speed range, the sprag elementsof the sprag clutch 912 remain engaged with the outer race and the innerrace due to the pre-loaded spring force and a resulting spring moment.When the example sprag clutch 912, inner race, and outer race rotate ata second operational speed range, the sprag elements of the sprag clutch912 become disengaged with the outer race and the inner race due to acentrifugal force and resulting centrifugal moment counteracting andsurpassing the spring moment. Further descriptions of the example spragclutch 912 and the operations thereof are provided below.

The example pump system 900 illustrated in FIG. 9 includes therolling-element bearing 914 to support the radial load of the rotorshaft 904 at the first operational speed range. Some examples of thefirst operational speed range include a first tangential speed range ofthe rotor shaft 904 and/or the foil bearing 916 from 0 m/s to 50 m/s, afirst fluid flow speed range exiting the pump system 900 from 0 m/s to10 m/s, etc. The example rolling-element bearing 914 includes an innerrace, an outer race, and rolling elements (e.g., balls, spheres,cylinders, etc.). The inner race and outer race of the examplerolling-element bearing 914 are able to rotate freely in eitherdirection. In some examples, the rolling-element bearing 914 includesliquid lubricant (e.g., oil, grease, etc.) to reduce the friction forceswithin the rolling-element bearing 914 and increase the lifespan of therolling-element bearing 914. If the example pump system 900 uses liquidlubricants for the rolling-element bearing 914, then an example oilseparator may be included in the pump system 900 to help ensure thefluid does not get contaminated. Some examples of oil separators thatcan be utilized in the examples disclosed herein are described infurther detail below. In some examples, the rolling-element bearing 914includes an inorganic grease (e.g., silicone grease, bentonite clay,polyurea, etc.) as a lubricant. The example rolling-element bearing 914illustrated in FIG. 9 uses a solid lubricant (e.g., silver coating,graphite, molybdenum disulfide, etc.) to reduce friction in therolling-element bearing 914 and to increase the lifespan of therolling-element bearing 914 while removing the risk of contaminating thefluid with liquid lubricants. The rolling-element bearing 914 can be oneof many types of rolling-element bearings familiar to those with skillin the art, such as cylindrical rolling-element bearings, angularcontact ball bearings, hybrid ceramic bearings, tapered rolling-elementbearings, deep groove single ball bearings, duplex ball bearings,spherical ball bearings, or any combination thereof. In some examples,the rolling-element bearing 914 is hermetically sealed from the examplefluid via one or more hermetic seals (e.g., piston seals, epoxy seal,ceramic-to-metal seal, etc.). The example rolling-element bearing 914may have a lifespan of 1000 hours or more depending on the type ofrolling-element bearing, the type of lubricant, and/or the effectivenessof the hermetic sealing. In some examples, the rolling-element bearing914 is externally cooled via conductive heat exchange from therolling-element bearing 914 to fuel, oil, air, and/or the thermaltransport bus 202 of FIG. 2 . Additionally or alternatively, anevaporative cooling system may be used to cool the examplerolling-element bearing 914.

The example pump system 900 illustrated in FIG. 9 includes the foilbearing 916 to support the radial load of the rotor shaft 904 at thesecond operational speed range. Some examples of the second operationalspeed range include a second tangential speed range of the rotor shaft904 and/or the foil bearing 916 from 50 m/s to 200 m/s, a second fluidflow speed range exiting the pump system 900 from 10 m/s to 100 m/s,etc. The example foil bearing 916 includes an inner lining, aspring-loaded foil, and a journal lining as described above. The innerlining and journal lining of the example foil bearing 916 are able torotate freely in either direction. The example foil bearing 916, theexample rolling-element bearing 914, the example sprag clutch 912, and,in general, the example integrated bearing system 910 are described ingreater detail below.

The example pump system 900 illustrated in FIG. 9 includes the bearinghousing 913 to support the rolling-element bearing 914 and the foilbearing 916. In some examples, the bearing housing 913 is an additivelymanufactured part that is designed to fit dimensions of therolling-element bearing 914 and the foil bearing 916. In some examples,the bearing housing 913 is fabricated via subtractive manufacturing tofit dimensions of the rolling-element bearing 914 and the foil bearing916. In some examples, the bearing housing 913 securely supports therolling-element bearing 914 and the foil bearing 916 via bolts, dowels,pins, adhesives, and/or interference fits.

FIG. 10 illustrates an enlarged view 1000 of the example integratedbearing system 910 of the pump system 900 for supporting radial loadsthat the rotor shaft 904 generates during operation of the pump system900. As shown in FIG. 10 , the enlarged view 1000 includes the rotorshaft 904, the integrated bearing system 910, the sprag clutch 912, thebearing housing 913, the rolling-element bearing 914, the foil bearing916, sprag elements 1002, a first inner race 1004, a first outer race1006, a second inner race 1008, and a second outer race 1010. Asmentioned earlier, the example components of the integrated bearingsystem 910 illustrated in FIG. 10 can be included in the example secondintegrated bearing system 918 illustrated in FIG. 9 . The exampleenlarged view 1000 of FIG. 10 illustrates the rotor shaft 904, theintegrated bearing system 910, the sprag clutch 912, the bearing housing913, the rolling-element bearing 914, and the foil bearing 916 aspreviously described in reference to FIG. 9 .

The example integrated bearing system 910 as illustrated in FIG. 10includes the sprag elements 1002 to engage the first inner race 1004 andthe first outer race 1006 such that the first inner race 1004 and thefirst outer race 1006 rotate simultaneously and with the same torqueoutput. Although two sprag elements 1002 are illustrated in FIG. 10 ,the example integrated bearing system 910 can include two or more spragelements 1002. As mentioned previously, the example sprag elements 1002are asymmetrically shaped such that when the sprag elements 1002 rotateabout an axis of rotation in a first direction, the sprag elements wedgebetween the first inner race 1004 and the first outer race 1006 andcreate friction forces between the components. The friction forces thatthe example sprag elements 1002 create occur between the sprag elements1002 and the first inner race 1004 as well as between the sprag elements1002 and the first outer race 1006. The friction forces that the spragelements 1002 create cause the first inner race 1004 and the first outerrace 1006 to rotate at a same angular velocity. As mentioned previously,the asymmetric shape of the sprag elements 1002 also allow the firstinner race 1004 and the first outer race 1006 to rotate freely in eitherdirection when the sprag elements 1002 rotate about the axis of rotationin a second direction opposite from the first direction. The spragelements 1002 and the operations thereof are described in greater detailbelow.

The example integrated bearing system 910 as illustrated in FIG. 10includes the first inner race 1004 to engage with the sprag elements1002 and the rolling-element bearing 914 at the first operational speedrange (e.g., tangential speed range of the rotor shaft 904 and/or thefoil bearing 916 from 0 m/s to 50 m/s, fluid flow speed range exitingthe pump system 900 from 0 m/s to 10 m/s, etc.). The example first innerrace 1004 illustrated in FIG. 10 is a hollow shaft that envelops therotor shaft 904 and is connected to the second inner race 1008 of therolling-element bearing 914 via bolts, adhesives, interference fits,etc. In some examples, the first inner race 1004 is manufactured (e.g.,subtractive machining or additive manufacturing) as the same part as thesecond inner race 1008. The example first inner race 1004 is longer thanthe second inner race 1008 and the second outer race 1010 such that thefirst inner race 1004 interfaces with the second inner race 1008 and thesprag elements 1002.

The example integrated bearing system 910 as illustrated in FIG. 10includes the first outer race 1006 to engage with the sprag elements1002 and the foil bearing 916 at the second operational speed range(e.g., tangential speed range of the rotor shaft 904 and/or the foilbearing 916 from 50 m/s to 200 m/s, fluid flow speed range exiting thepump system 900 from 10 m/s to 100 m/s, etc.). The example first outerrace 1006 illustrated in FIG. 10 is a shaft that is connected to therotor shaft 904 via bolts, adhesives, interference fits, etc. In someexamples, the first outer race 1006 is manufactured (e.g., subtractivemachining or additive manufacturing) as the same part as the rotor shaft904. The example first outer race 1006 is designed such that the firstouter race 1006 interfaces with the sprag elements 1002 and the innerlining of the example foil bearing 916.

FIG. 11 illustrates an example disengaging-type sprag clutch 1100 (e.g.,sprag clutch 912 of FIGS. 9 and/or 10 ) of the example integratedbearing system 910 for engaging and/or disengaging an examplerolling-element bearing (e.g., rolling-element bearing 914 of FIGS. 9and/or 10 ) and/or an example foil bearing (e.g., foil bearing 916 ofFIGS. 9 and/or 10 ). The example sprag clutch 1100 illustrated in FIG.11 is shown from an isometric viewpoint 1102 and from a front-facingviewpoint 1104. The example sprag clutch 1100 illustrated in FIG. 11includes sprag elements 1106 (e.g., sprag elements 1002 of FIG. 10 ), aninner ring 1108, and an outer ring 1110. Although the front-faceviewpoint 1104 of the example sprag clutch 1100 illustrates twenty-sixsprag elements 1106, more or less than twenty-six sprag elements can beincluded in the example sprag clutch 1100 of FIG. 11 and/or the examplesprag clutch 912 of FIGS. 9 and/or 10 .

The example sprag clutch 1100 illustrated in FIG. 11 includes the innerring 1108 and the outer ring 1110. The example inner ring 1108 isring-shaped and includes slots that are shaped to fit a bottom portionof the sprag elements 1106. The example outer ring 1110 is alsoring-shaped and includes slots that are shaped to fit an upper portionof the sprag elements 1106. The slots included in the example inner ring1108 and the example outer ring 1110 are designed such that theasymmetrical figure-eight shape of the sprag elements 1106 hook into theslots. The example sprag elements 1106, inner ring 1108, and outer ring1110 are also designed such that the top and bottom surfaces of thesprag elements 1106 are protruding outward from the outer ring 1110 andinward from the inner ring 1108. In some examples, the inner ring 1108and/or the outer ring 1110 are coupled to the sprag elements 1106 viarods, pins, screws, etc. to retain the position of the sprag elements1106 in between an inner race (e.g., the first inner race 1004) and anouter race (e.g., the first outer race 1006). In some examples, theinner ring 1108 and/or the outer ring 1110 retain the position of thesprag elements 1106 without fasteners (e.g., bolts, pins, rods, etc.).In some examples, the sprag elements 1106, the inner ring 1108, and/orthe outer ring 1110 are manufactured separately and are assembledtogether to form the sprag clutch 1100. In some examples, the spragelements 1106, the inner ring 1108, and/or the outer ring 1110 aremanufactured via additive manufacturing, such as direct metal lasersintering, either separately as parts to be assembled or as a fabricatedassembly. In some examples, the sprag clutch 1100 includes a springribbon to apply a pre-loaded spring force on the sprag elements 1106causing the sprag elements 1106 to engage with the inner ring 1108 andthe outer ring 1110 prior to operation and while the example pump system900 is operating within the first operation speed range.

FIG. 12A illustrates an example engaged state 1200A of an example spragelement 1202 (e.g., sprag element 1002 and/or one of the sprag elements1106). The example engaged state 1200A illustrated in FIG. 12A shows thesprag element 1202 with a sprag axis of rotation 1204 about which thesprag element 1202 rotates. In some examples, the sprag axis of rotation1204 is also a location of a center of gravity (CG) of the sprag element1202. The example sprag element 1202 engages with an inner race 1206(e.g., inner race 1004) and an outer race 1208 (e.g., outer race 1006)prior to operation of the pump system 900 due to a pre-loaded springforce acting on the sprag element 1202. In some examples, a springribbon is included in the sprag clutch (e.g., sprag clutch 1100) toapply the pre-loaded spring force on the left side of the sprag element1202 above the sprag axis of rotation 1204, relative to the orientationillustrated in FIG. 12A. The pre-loaded spring force acting on the spragelement 1202 creates a spring moment 1210 on the sprag element 1202. Theexample spring moment 1210 causes the sprag element 1202 to wedge and/orjam between the inner race 1206 and the outer race 1208 prior tooperation of the pump system 900. When the pump system 900 beginsoperation, and the outer race 1208 is rotating in a counterclockwisedirection (relative to the orientation illustrated in FIG. 12A), andfriction forces are generated between the sprag element 1202, the outerrace 1208, and the inner race 1206 causing the inner race 1206 to rotatecounterclockwise at a same rate as the outer race 1208. The examplespring ribbon is designed to create a large enough spring moment 1210 tocounteract frictional moment(s) on the sprag element 1202 acting in acounterclockwise direction, opposing the spring moment 1210. At thispoint in the operation of the example pump system 900, a point ofcontact between the sprag element 1202 and the outer race 1208 is to theright of the sprag axis of rotation 1204 and the CG of the sprag element1202. The example point of contact is also the location at which thefrictional force and a resulting frictional moment act on the spragelement 1202. During operation of the example pump system 900 at thefirst operational speed range, a centrifugal force is acting on thesprag element 1202 at the sprag axis of rotation 1204 and/or the CG ofthe sprag element 1202. Since the sprag axis of rotation 1204 and/or theCG of the sprag element 1202 is to the left of the point of contact atthe first operational speed range, the centrifugal force creates a firstcentrifugal moment acting in the same direction as the spring moment,opposing the frictional moment(s). Thus, while an example shaft (e.g.,rotor shaft 904) drives the rotation of the outer race 1208 at the firstoperational speed range via a mechanical connection (e.g., bolts,adhesives, interference fit, etc.), the sprag element 1202 remainsengaged with the outer race 1208 and the inner race 1206, which causesthe inner race 1206 to rotate at the same rate as the outer race 1208.The example sprag element 1202 remains engaged with the inner race 1206and the outer race 1208 as long as the outer race 1208 continues torotate at an angular velocity within the first operational speed range(e.g., less than the foil bearing liftoff speed (e.g., rotor shaft 904and/or foil bearing 916 tangential velocity of 10 m/s to 50 m/s)) due tothe design, shape, structure, materials, etc. of the example springribbon.

FIG. 12B illustrates an example disengaged state 1200B of the examplesprag element 1202 (e.g., sprag element 1002 and/or one of the spragelements 1106). The example disengaged state 1200B illustrated in FIG.12B shows the same sprag element 1202 with the same sprag axis ofrotation 1204 and/or CG about which the sprag element 1202 rotates. Theexample disengaged state 1200B illustrated in FIG. 12B includes the sameinner race 1206 and the same outer race 1208 as FIG. 12A. In theillustrated disengaged state 1200B of FIG. 12B, the outer race 1208(e.g., outer race 1006) is connected to the example shaft (e.g., rotorshaft 904) and is rotating at a rate that is within the secondoperational speed range (e.g., greater that the foil bearing liftoffspeed (e.g., tangential velocity of 10 m/s to 50 m/s)). Once the outerrace 1208 and the shaft (e.g., rotor shaft 904) are rotating at a ratewithin the second operational speed range, the sprag element 1202disengages from the outer race 1208 and the inner race 1206 and counterrotates in a counterclockwise direction. As the example pump system 900increases the operational speed closer to the lower limit of the secondoperational speed range, the frictional forces and frictional momentsacting on the sprag element 1202 increase. The frictional moments actingon the sprag element 1202 counteract the spring moments 1210. Once theoperational speed of the pump system 900 reaches the lower limit of thesecond operational speed range, the frictional moment is able tocounteract the spring moment 1210 enough such that the sprag axis ofrotation 1204 and/or the CG of the sprag element 1202 moves to the rightof the point of contact between the sprag element and the outer race1208. Once the example point of contact shifts to the left of the spragaxis of rotation 1204 and/or the CG of the sprag element 1202, the firstcentrifugal moment switches directions and becomes a second centrifugalmoment 1212 that complements the frictional moment and opposes thespring moment 1210. Once the summation of the frictional moments and thesecond centrifugal moment 1212 surpass the spring moment 1210, the spragelement 1202 disengages from the inner race 1206 and the outer race1208. Thus, in response to an example shaft (e.g., rotor shaft 904)driving the outer race 1208 to rotate at the second operational speedrange via the mechanical connection (e.g., bolts, adhesives,interference fit, etc.), the sprag element 1202 disengages from theouter race 1208 and the inner race 1206, which causes the inner race1206 to rotate freely from the outer race 1208.

FIG. 13 illustrates an example integrated bearing system 1300 (e.g.,integrated bearing system 910 of FIGS. 9 and 10 ) and example load pathsthat the integrated bearing system 1300 supports during at differentpoints during an operation of an example pump system (e.g., pump system900 of FIG. 9 ). The example integrated bearing system 1300 includes ashaft 1302 (e.g., rotor shaft 904 of FIGS. 9 and/or 10 ), a bearinghousing 1304 (e.g., bearing housing 913 of FIGS. 9 and/or 10 ), a spragclutch 1306 (e.g., sprag clutch 912 of FIGS. 9 and/or 10 ), an innerrace 1308 (e.g., inner race 1004 of FIG. 10 and/or inner race 1206 ofFIGS. 12A and/or 12B), an outer race 1310 (e.g., outer race 1006 of FIG.10 and/or outer race 1208 of FIGS. 12A and/or 12B), a rolling-elementbearing 1312 (e.g., rolling-element bearing 914 of FIGS. 9 and/or 10 ),a foil bearing 1314 (e.g., foil bearing 916 of FIGS. 9 and/or 10 ), afirst load path 1316, and a second load path 1318. The example firstload path 1316 and the example second load path 1318 are representationsof forces acting upon the example inner race 1308 and the example outerrace 1310, respectively, and are not physical objects.

As described previously and illustrated in FIGS. 9 and/or 10 , theexample outer race 1310 is connected to the example shaft 1302 viamechanical fasteners (e.g., bolts, screws, dowels, adhesives,interference fits, etc.). As also previously described, the examplebearing housing 1304 securely supports the example rolling-elementbearing 1312 and the example foil bearing 1314 in place during operationvia mechanical fasteners (e.g., bolts, screws, dowels, adhesives,interference fits, etc.). As the example shaft 1302 rotates at a firstangular velocity associated with a first tangential velocity that doesnot satisfy the foil bearing liftoff speed (e.g., tangential velocity of10 m/s to 50 m/s), the example sprag clutch 1306 engages with theexample outer race 1310 and the example inner race 1308. In response tothe example sprag clutch 1306 engaging with the inner race 1308 and theouter race 1310 at the first operational speed range, the shaft 1302generates the example first load path 1316 which acts on the inner race1308 and the rolling-element bearing 1312. Thus, at the firstoperational speed range, the example rolling-element 1312 supports aweight of the shaft 1302.

As described previously and illustrated in FIGS. 12A and 12B, theexample sprag clutch 1306 disengages from the inner race 1308 and theouter race 1310 at a second angular velocity associated with a secondtangential velocity that satisfies the foil bearing liftoff speed (e.g.,tangential velocity of 10 m/s to 50 m/s). In response to the spragclutch 1306 disengaging from the inner race 1308 and the outer race 1310at the second tangential velocity, the shaft 1302 generates the examplesecond load path 1318 which acts on the inner outer race 1310 and thefoil bearing 1314. Thus, at the second operational speed range, theexample foil bearing 1314 supports the weight of the shaft 1302. In someexamples, the first load path 1316 and the second load path 1318 are ofa same force value which is sufficiently similar to the weight of theshaft 1302.

FIG. 14 is a flow diagram illustrating an example process or operation1400 that the integrated bearing system 910 may follow as disclosedherein to dynamically support a rotor shaft 904 in a pump system 900.While the operation 1400 is described with primary reference todynamically supporting the rotor shaft 904 in the pump system 900 ofFIG. 9 , the operation 1400 can be used to support another rotatingshaft in another pump system with the integrated bearing system 910.While the operation 1400 is described with primary reference todynamically supporting the rotor shaft 904 with the integrated bearingsystem 910, another integrated bearing system (e.g., integrated bearingsystem 918) can use the operation 1400 to dynamically support the rotorshaft 904 or another rotor shaft.

At block 1402, a pump system 900 begins to pressurize a fluid (e.g.,heat exchange fluid, supercritical fluid, supercritical carbon dioxide(sCO₂), etc.) flowing through a thermal management system and increasethe flow rate of the fluid exiting the pump system 900. For example, anelectrical current is supplied to a stator 906 in a motor of the pumpsystem 900 which causes electromagnets in the stator 906 to produce oneor more magnetic fields that alternate polarities over time based on thedirection of electric current flowing through the stator 906. Themagnetic field(s) produced are perpendicular to an axis of rotation of arotor 905 in the motor. The rotor 905 is attached to the rotor shaft 904and includes permanent magnets that are attracted to and/or repelledfrom the alternating polarities of the electromagnets in the stator 906.As the rotor shaft 904 rotates with increasing angular velocity, so doesan impeller 902 which is coupled to the rotor shaft 904. The impeller902 includes vanes or blades that causes the fluid pressure and flowrateto increase.

At block 1404, the integrated bearing system 910 of the pump system 900engages with an inner race 1004 attached to a rolling-element bearing914 and an outer race 1006 attached to the rotor shaft 904. For example,a sprag clutch 912 of the integrated bearing system 910 includes spragelements 1002 (e.g., sprag elements 1106 of FIG. 11 ) that are engagedwith the inner race 1004 and the outer race 1006 due to a pre-loadedspring force acting on the sprag elements 1002. When the sprag elements1002 wedge between the outer race 1006 and the inner race 1004, reactionforces and frictional forces are generated that cause the inner race1004 to rotate at a same rate as the outer race 1006.

At block 1406, the integrated bearing system 910 of the pump system 900supports the rotor shaft 904 via the inner race 1004. For example, theouter race 1006 rotates at the same rate as the rotor shaft 904, thesprag clutch 912 engages with the outer race 1006 and the inner race1004, the inner race 1004 rotates at the same rate as the outer race1006 and the rotor shaft 904, and the rolling-element bearing 914supports the radial load of the rotor shaft 904 via the inner race 1004.

At block 1408, the pump system 900 increases the operating speed of themotor. For example, electric current is supplied to the stator 906 at agreater rate causing the electromagnets in the stator 906 to alternatein polarity at a greater rate. As the electromagnets of the stator 906alternate at a greater rate, the angular velocity of the rotor 905increases at the same rate. As the angular velocity of the rotor 905 andthe connected rotor shaft 904 increases, the tangential velocity of therotor shaft 904 and the outer race 1006 also increases.

At block 1410, if the tangential velocity of the rotor shaft A104 and/orthe outer race 1006 satisfies a foil bearing liftoff speed (e.g., 10 m/sto 50 m/s), then operation 1400 proceeds to block 1412. If thetangential velocity of the rotor shaft A104 and/or the outer race 1006does not satisfy the foil bearing liftoff speed, then operation 1400returns to block 1406, at which the rolling-element bearing 914continues to support the weight of the rotor shaft 904 via the innerrace 1004.

At block 1412, the integrated bearing system 910 disengages from theinner race 1004 and the outer race 1006. For example, once thetangential velocity of the rotor shaft A104 and/or the outer race 1006are high enough as to satisfy the foil bearing liftoff speed, thecentrifugal forces and frictional forces acting on the sprag elements1002 of the sprag clutch 912 counteract and surpass spring momentforces, causing the sprag elements 1002 to counter rotate and disengagefrom the inner race 1004 and the outer race 1006.

At block 1414, the integrated bearing system 910 supports the radialload that the rotor shaft A104 produces via the outer race 1006. Forexample, once the sprag elements 1002 disengage from the outer race 1006and the inner race 1004, the foil bearing 916 supports the total weightand/or the majority of the weight of the rotor shaft A104 via the outerrace 1006 which is connected to the rotor shaft 904 and interacts withthe foil bearing 916. The foil bearing 916 continues to support thetotal and/or the majority of the radial load of the rotor shaft A104 aslong as the foil bearing liftoff speed is satisfied.

At block 1416, if the tangential velocity of the rotor shaft A104 and/orthe foil bearing 916 continues to satisfy the foil bearing liftoffspeed, then the operation 1400 returns to block 1414, at which theintegrated bearing system 910 continues to support the radial load ofthe rotor shaft 904 via the outer race 1006. If the operational speed ofthe pump system 900 slows down such that the tangential velocity of therotor shaft 904 and/or the foil bearing 916 does not satisfy the foilbearing liftoff speed, then operation 1400 proceeds to block 1418.

At block 1418, the integrated bearing system 910 of the pump system 900engages with the inner race 1004 attached to the rolling-element bearing914 and the outer race 1006 attached to the rotor shaft 904. Forexample, the spring moment forces acting on the sprag elements surpassesopposing frictional forces and centrifugal forces, and the sprag clutch912 of the integrated bearing system 910 engages with the inner race1004 and the outer race 1006. At block 1420, the integrated bearingsystem 910 supports the radial load of the rotor shaft 904 via the innerrace 1004. For example, sprag clutch 912 of the integrated bearingsystem 910 engages with the inner race 1004 attached to therolling-element bearing 914, and the rolling-element bearing 914supports the total and/or the majority of the radial load of the rotorshaft 904 via the inner race 1004. The operation 1400 continues at block1420 until the pump system 900 stops operating, at which point theoperation 1400 of FIG. 14 ends.

In some examples, the pump system 900 includes means for increasingkinetic energy. For example, the means for increasing may be implementedby the impeller 902, the rotor shaft 904, the rotor 905, and/or thestator 906 of FIG. 9 . In some examples, the means for increasing mayinclude an electric motor, an impeller shaft, and an impeller.

In some examples, the pump system 900 includes means for providingtorque. For example, the means for providing may be implemented by thestator 906 and/or the rotor 905 of FIG. 9 . In some examples, the meansfor providing may include an electric motor.

In some examples, the pump system 900 includes means for firstsupporting. For example, the means for first supporting may beimplemented by the first integrated bearing system 910 of FIGS. 9 and/or10 , the second integrated bearing system 918 of FIG. 9 , the firstrolling-element bearing 914 of FIGS. 9 and/or 10 , the secondrolling-element bearing 922 of FIG. 9 , the integrated bearing system1300 of FIG. 13 , and/or the rolling-element bearing 1312 of FIG. 13 .In some examples, the means for first supporting may include an angularcontact ball bearing, a hybrid ceramic bearing, a taper roller bearing,a deep groove single ball bearing, a duplex ball bearing, and/or aspherical bearing.

In some examples, the pump system 900 includes means for secondsupporting. For example, the means for second supporting may beimplemented by the first integrated bearing system 910 of FIGS. 9 and/or10 , the second integrated bearing system 918 of FIG. 9 , the first foilbearing 916 of FIGS. 9 and/or 10 , the second foil bearing 924 of FIG. 9, the integrated bearing system 1300 of FIG. 13 , and/or the foilbearing 1314 of FIG. 13 . In some examples, the means for secondsupporting may include an air foil bearing and/or a fluid static foilbearing.

In some examples, the pump system 900 includes means for engaging. Forexample, the means for engaging may be implemented by the firstintegrated bearing system 910 of FIGS. 9 and/or 10 , the secondintegrated bearing system 918 of FIG. 9 , the first sprag clutch 912 ofFIGS. 9 and/or 10 , the second sprag clutch 920 of FIG. 10 , the spragelements 1002 of FIG. 10 , the sprag clutch 1100 of FIG. 11 , the spragelements 1106 of FIG. 11 , the sprag element(s) 1202 of FIGS. 12A-12B,and/or the sprag clutch F506 of FIG. 13 . In some examples, the meansfor engaging may include a clutch and/or one or moreasymmetrically-shaped rotating elements.

In some examples, the pump system 900 includes means for separating. Forexample, the means for separating may be implemented by an oilseparator. Further descriptions on example oil separators that may beimplement the means for separating are discussed in greater detailbelow.

Example integrated bearing systems for dynamically supporting shafts inpump systems are disclosed herein. The example integrated bearing systemdisclosed herein includes a sprag clutch, an inner race attached to arolling-element bearing, and an outer race attached to a foil bearingand a rotor shaft. The example integrated bearing system disclosedherein includes the sprag clutch to engage with the inner race and theouter race at a first operational speed range (e.g., tangential speedrange from 0 m/s to 10 m/s and/or 50 m/s). Thus, the examplerolling-element bearing supports a radial load that the example rotorshaft generates while operating within the first operational speedrange. The example integrated bearing system disclosed herein alsoincludes the sprag clutch to disengage with the inner race and the outerrace at a second operational speed range (e.g., tangential speed rangefrom 10 m/s and/or 50 m/s to 200 m/s) due to centrifugal forces actingon sprag elements of the sprag clutch. Thus, the example foil bearingsupports the radial load that the example rotor shaft generates whileoperating within the second operational speed range. The exampleintegrated bearing systems disclosed herein reduce wear of the foilbearings in the example pump systems (relative to example pump systemswithout the integrated bearing systems) because the rolling-elementbearings support the majority of and/or the total radial loads of therotor shaft during start-up and stopping speeds of the pump system. Theexample integrated bearing systems disclosed herein allow the foilbearings to operate longer periods of time without damage and/ormaintenance (relative to foil bearings in pump systems without theexample integrated bearing systems) since the example foil bearingssupport the majority of and/or the total radial loads of the rotor shaftwith air pressure in the foil bearings (not a spring-loaded foil withinthe foil bearings) while the foil bearing is operating at the secondoperational speed range.

Layered Barrier Cans for Magnetic Couplings and Methods of Producing theSame

In some known pumps, to reduce an impact of a barrier can (e.g., thebarrier can 452 of FIG. 4 ) on the magnetic fields produced by themagnetic couplings (e.g., the first magnetic coupling 450 and the secondmagnetic coupling 460 of FIG. 4 ), a non-metallic material is utilizedfor the barrier can. For instance, the barrier can may include aplastic. However, a plastic barrier can include a bulky thickness toprovide sufficient structural strength and still is often not strongenough to withstand high pressures (e.g., pressures over 1,000pounds-per-square-inch absolute (PSIA)). Additionally, the non-metallicmaterial may deform under higher temperatures. As such, usage ofnon-metallic materials for barrier cans limits potential operatingpressures and/or temperatures of the associated pump. Accordingly, thenon-metallic barrier can limits a rate at which the fluid can be driventhrough the thermal transport bus 202 and, in turn, limits a rate atwhich thermal energy can be transferred between the fluid and a workingfluid.

In some pumps, to enable the barrier can to withstand increasedpressures (e.g., pressures over 1,000 PSIA), the barrier can is formedof titanium. However, the titanium barrier can causes eddy current lossbetween the rotating magnetic fields produced by the magnetic couplings.Further, such eddy current loss is increased when the titanium barriercan includes a greater thickness to withstand higher pressures. As such,the titanium barrier can may limit a rate at which the magneticcouplings can rotate while staying magnetically coupled. Accordingly,the titanium barrier can affect the torque transferred between a motorshaft and an impeller shaft. Moreover, to overcome the eddy currentloss, the titanium barrier may require larger magnets to be utilized forthe magnetic couplings, which increases a size and/or a cost of thepump, requires a larger motor to drive the rotation of the magneticcouplings, and/or requires a cooling arrangement to relieve heatgenerated by the magnetic couplings during rotation.

FIG. 15 illustrates a first example shroud 1500 (e.g., a barrier can)that can be utilized in the thermal transport bus pump 400 (e.g., thebarrier can 452 of FIG. 4 ), the pump system 500 of FIG. 5 (e.g., thebarrier can 536 of FIG. 5 ), the pump system 600 of FIG. 6 (e.g., thebarrier can 636 of FIG. 6 ), the pump system 700 of FIG. 7 , and/or anyother pump systems disclosed herein that utilize a barrier can or shroudto contain a flow of fluid. In the illustrated example of FIG. 15 , theshroud 1500 includes an inner shell 1502, an outer shell 1504, and acore shell 1506 (e.g., a metal core shell, a metallic core layer, etc.)positioned between the inner shell 1502 and the outer shell 1504. Theshroud 1500 defines a cavity 1508. Accordingly, when the shroud 1500 isimplemented in the thermal transport bus pump 400, one magnetic coupling(e.g., the second magnetic coupling 460 of FIG. 4 ) can be positioned inthe cavity 1508 and another magnetic coupling (e.g., the first magneticcoupling 450 of FIG. 4 ) can be positioned around the shroud 1500.Accordingly, the inner shell 1502 can be in contact with a first fluid(e.g., a heat exchange fluid such as a supercritical fluid (e.g., sCO₂,etc.)) and the outer shell 1504 can be in contact with a second fluid(e.g., air, hydrogen, etc.).

In the illustrated example of FIG. 15 , an inner surface 1510 of thecore shell 1506 is fully in contact with the inner shell 1502.Similarly, an outer surface 1512 of the core shell 1506 is fully incontact with the outer shell 1504. Specifically, the inner shell 1502and the outer shell 1504 provide insulating layers that surround thecore shell 1506. As a result, the continuous surface contact that thecore shell 1506 has with the inner shell 1502 and the outer shell 1504can help the core shell 1506 dissipate heat generated as of result ofthe core shell 1506 encountering rotating magnetic fields. Specifically,the inner shell 1502 can transfer thermal energy between the first fluidand the core shell 1506. Further, the outer shell 1504 can transferthermal energy between the second fluid and the core shell 1506. Thethermal transport bus pump 400 can cause the first fluid to berecirculated to increase a rate at which the thermal energy istransferred between the core shell 1506 and the first fluid through theinner shell 1502. Moreover, the vent 461 (FIG. 4 ) can enable the secondfluid to circulate in the coupling housing 424 (FIG. 4 ). In someexamples, a fan drives the second fluid into and/or out of the couplinghousing to increase a rate at which the thermal energy is transferredbetween the core shell 1506 and the second fluid through the outer shell1504. In some other examples, the coupling housing 424 and/or the motorhousing 412 (FIG. 4 ) is filled with the second fluid, which enables thesecond fluid to circulate and cool the shroud 1500 when the couplinghousing 424 does not include the vent 461.

In FIG. 15 , the shroud 1500 can include a thickness between 0.090inches (in.) and 0.125 in. In some examples, the inner shell 1502includes a first thickness (e.g., between 0.005 in. and 0.040 in.), theouter shell 1504 includes the first thickness or a second thickness(e.g., between 0.005 in. and 0.040 in.), and the core shell 1506includes a third thickness (e.g., between 0.005 in. and 0.090 in.). Insome examples, the third thickness is greater than the first thicknessand the second thickness. However, the third thickness couldalternatively be smaller than the first thickness and/or the secondthickness or approximately equivalent to the first thickness and/or thesecond thickness. The thickness of the shroud 1500 and, morespecifically, the inner shell 1502, the outer shell 1504, and the coreshell 1506 can be based on pressures encountered during operations of anassociated pump (e.g., the thermal transport bus pump 400). For example,the shroud 1500 can include a first thickness (e.g., 0.125 in.) when thepump 400 is to operate with a first maximum pressure, and the shroud1500 can include a second thickness (e.g., 0.090 in.) when the pump 400is to operate with a second maximum pressure less than the first maximumpressure.

In the illustrated example of FIG. 15 , the inner shell 1502, the outershell 1504, and the core shell 1506 respectively include uniformthicknesses. In some examples, the inner shell 1502, the outer shell1504, and/or the core shell 1506 respectively include non-uniformthicknesses, as discussed in further detail below.

The inner shell 1502 and the outer shell 1504 include a non-metallicmaterial, such as a ceramic material, a polymer material, and/or acomposite material. In some examples, the ceramic material isaluminum(I) oxide (Al₂O), aluminum(II) oxide (AlO) (e.g., aluminummonoxide), aluminum(III) oxide (Al₂O₃) (e.g., aluminum oxide, alumina),zirconia (e.g., zirconia toughened alumina), and/or silicon carbide. Insome examples, the polymer material and/or the composite materialincludes a carbon fiber composite and/or a polyimide (e.g., T650-35,PMR-15, MVK-14 standard modulus, etc.). The carbon fiber composite caninclude short carbon fibers, long carbon fibers, and/or endless carbonfibers. Accordingly, the inner shell 1502 defines a first non-metalliclayer of the shroud 1500 and the outer shell 1504 defines a secondnon-metallic layer of the shroud 1500. In some examples, the inner shell1502 and the outer shell 1504 both include the ceramic material. In someexamples, the inner shell 1502 and the outer shell 1504 both include thepolymer. In some examples, the inner shell 1502 and the outer shell 1504both include the composite material. In some examples, the inner shell1502 includes a first material, such as the ceramic material, and theouter shell 1504 includes a second material different from the firstmaterial, such as the polymer or the composite material. Further, thecore shell 1506 includes nickel and/or cobalt. Additionally oralternatively, the core shell 1506 can include a different metal.

In FIG. 15 , the shroud 1500 includes a flange portion 1514. In FIG. 4 ,the inner shell 1502, the outer shell 1504, and the core shell 1506extend circumferentially outward to form the flange portion 1514.Accordingly, the O-ring 459 of FIG. 4 can be positioned around theflange portion 1514. Further, the flange portion 1514 can be pressedagainst the aft end of the forward bearing housing 428 of FIG. 4 via thebarrier can retainer 454 and the bolts 458 of FIG. 4 . As the innershell 1502 and the outer shell 1504 enclose the core shell 1506, theO-ring 459 presses against the outer shell 1504 to enable the shroud1500 to hermetically seal off the aft end of the forward bearing housing428.

The inner shell 1502 can be formed via molding and/or slurry-basedprocessing techniques, such as additive manufacturing (e.g., thermalspraying, cold spraying, etc.) and/or sintering. In some examples, whenthe inner shell 1502 is formed via thermal spraying and/or coldspraying, there is an initial mandrel upon which the inner shell 1502 issprayed and subsequently separated from. In some examples, when theinner shell 1502 is formed via thermal spraying and/or cold spraying, aninitial portion (e.g., an inner or outer portion) of the inner shell1502 can be formed via another manufacturing technique, such asslurry-based processing, and a remainder of the inner shell 1502 can besprayed onto the initial portion. Further, the initial portion of theinner shell 1502 can be machined to a certain thickness in advance ofthe thermal spraying and/or cold spraying. In some examples, the innershell 1502 can be formed via other manufacturing techniques, such ascasting (e.g., slip casting, tape casting, etc.) and/or pressing.

In turn, the core shell 1506 is electroformed (e.g., electrodeposited)on an outer surface 1516 of the inner shell 1502. That is, the innershell 1502 serves as a mandrel on which the core shell 1506 is formed.Advantageously, electroforming the core shell 1506 enables the thicknessof the core shell 1506 to be reduced compared to thicknesses providableby conventional manufacturing techniques utilized to shape metals.

Further, the outer shell 1504 can be formed via thermal spraying or coldspraying on the core shell 1506. Accordingly, the electroformed layer ofthe core shell 1506 can serve as a bond coating for the outer shell1504. In some examples, the inner shell 1502 can be formed via othermanufacturing techniques, such as a composite lay-up process (e.g.,composite layer laying), molding (e.g., injection molding), slipcasting, pressing, and/or tape casting.

For example, the inner shell 1502 can be molded, the core shell 1506electroformed on the inner shell 1502, and the outer shell 1504 thermalsprayed on the core shell 1506. In some examples, the core shell 1506 iselectroformed on an inner surface of the outer shell 1504 instead of theouter surface of the inner shell 1502. In turn, the inner shell 1502 canbe thermal sprayed or cold sprayed on the core shell 1506. Furthermore,the shroud 1500 can be finished via machining or grinding to maintain athickness of the shroud 1500 within a certain tolerance range and definea uniform contour along the inner surface of the inner shell 1502 and/oran outer surface of the outer shell 1504.

Advantageously, the core shell 1506 enables the first example shroud1500 to withstand an increased pressure without rupturing and, in turn,enables the thermal transport bus pump 400 to drive the fluid at higherpressures. Specifically, the first example shroud 1500 enables the speedof the motor 410 to be increased to increase an output (e.g., avolumetric flowrate) produced by the impeller 406. As a result, thethermal transport bus pump 400 can provide more of the fluid to areas ofthe aircraft 10 of FIG. 1 and/or the gas turbine engine 100 of FIG. 2over a shorter period to enable heat transfer between the fluid and theworking fluids in the aircraft 10 of FIG. 1 and/or the gas turbineengine 100 to occur at a faster rate. Further, a geometry of the innershell 1502, the outer shell 1504, and/or the core shell 1506 can benon-cylindrical to increase a stiffness of the first shroud 1500 and, inturn, increase a pressure that the shroud 1500 is able to withstand.

Moreover, electroforming the core shell 1506 enables the core shell 1506to be formed with a reduced thickness that conventional manufacturingtechniques are unable to produce. As a result, when the first shroud1500 is implemented in the thermal transport bus pump 400, the coreshell 1506 causes a reduced eddy current loss compared to known barriercans that include metal. Accordingly, the reduced eddy current lossenables a size of the motor 410, the first magnetic coupling 450, andthe second magnetic coupling 460 to be reduced. Moreover, the reducededdy current loss reduces thermal energy generated by the core shell1506 as a result of the rotating magnetic fields produced by the firstmagnetic coupling 450 and the second magnetic coupling 460 of FIG. 4 .As such, electroforming the core shell 1506 prevents a need for acooling sleeve around the coupling housing 424. Additionally, the coreshell 1506 increases a temperature range that the shroud 1500 is able towithstand.

Similarly, thermal spraying enables the inner shell 1502 and/or theouter shell 1504 to be formed with a reduced thickness. Thus, an overallthickness of the first shroud 1500 is minimized or otherwise reduced,which enables a gap between the first magnetic coupling 450 and thesecond magnetic coupling 460 to be minimized or otherwise reduced. Assuch, torque can be transferred between the motor shaft 438 and theimpeller shaft 466 more efficiently with smaller magnets and/or asmaller motor to reduce a size and/or a cost of the thermal transportbus pump 400. Additionally, the reduced thickness of the inner shell1502 and/or the outer shell 1504 and/or the continuous surface contactthat the core shell 1506 has with the inner shell 1502 and the outershell 1504 enables the inner shell 1502 and/or the outer shell 1504 totransfer thermal energy between encountered fluids and the core shell1506 more efficiently. Accordingly, the inner shell 1502 and/or theouter shell 1504 can help the core shell 1506 dissipate heat.Furthermore, the reduced eddy current loss caused by the shroud 1500 andthe reduced thickness of the shroud 1500 can enable an increasedseparation between the shroud 1500 and the magnetic couplings 450, 460such that fluids can flow between the shroud 1500 and the magneticcouplings 450, 460 at an increased flow rate to increase a rate at whichthermal energy is transferred between the shroud 1500 and the fluids.

Furthermore, reducing the thickness of the first shroud 1500 andreducing the eddy current loss caused by the shroud 1500 enables therotation of the first magnetic coupling 450 and the second magneticcoupling 460 to remain interlocked at greater rotational speeds.Accordingly, the first shroud 1500 enables the thermal transport buspump 400 to drive the fluid with an increased flow rate and/or anincreased pressure.

FIG. 16 illustrates another example inner shell 1600 that can beutilized in the first example shroud 1500 of FIG. 15 (e.g., the innershell 1502 of FIG. 15 ). In FIG. 16 , the inner shell 1600 includes abase portion 1602 and ribs 1604 (e.g., ridges) radially protruding fromthe base portion 1602. Specifically, the ribs 1604 extend away from acavity 1606 (e.g., the cavity 1508) defined by the base portion 1602.Accordingly, a first portion of the inner shell 1600 includes a firstthickness defined by the base portion 1602 and a second portion of theinner shell 1600 includes a second thickness defined by the base portion1602 and the ribs 1604. In some examples, the second thickness isbetween 0.75 inches and 1.0 inches. Advantageously, the ribs 1604 enablethe shroud 1500 of FIG. 15 to provide an increased structural stiffnessand, thus, increases a maximum pressure that the shroud 1500 is able towithstand.

In the illustrated example of FIG. 16 , the ribs 1604 are spaced apartalong a circumference of the base portion 1602. Further, thecircumferentially spaced ribs 1604 extend along the base portion 1602 inan axial direction A defined by the inner shell 1600. In the illustratedexample of FIG. 16 , the ribs 1604 extend in straight lines along theaxial direction A. However, it should be understood that the ribs 1604can extend along the base in any shape to increase a stiffness of theshroud 1500 of FIG. 15 . For example, the ribs 1604 can extend from thebase portion 1602 in straight lines not defined by the axial direction(e.g., where a circumferential position of a first end of a ridge variesfrom a circumferential position of a second end of the ridge). In someexamples, the ribs 1604 extend along the base portion 1602 in a spiralalong the axial direction A. In some examples, the ribs 1604 extendalong the base portion 1602 in a circumferential direction C defined bythe inner shell 1600. In some examples, the ribs 1604 includes wavessuch that positions of the ribs 1604 vary in the circumferentialdirection C as the ribs 1604 extend in the axial direction A along thebase portion 1602.

Furthermore, the core shell 1506 of FIG. 15 can be electroformed on theinner shell 1600. Accordingly, the core shell 1506 of FIG. 15 is layeredon the base portion 1602 and the ribs 1604 of the inner shell 1600. As aresult, the core shell 1506 of FIG. 15 can include a first portion fixedto the base portion 1602 and a second portion fixed to the ribs 1604.Accordingly, the first portion of the core shell 1506 of FIG. 15 caninclude a first inner diameter and a first outer diameter and the secondportion of the core shell 1506 can include a second inner diameter and asecond outer diameter greater than the first inner diameter and thefirst outer diameter. In turn, a geometry of the core shell 1506 canfurther increase the structural stiffness of the shroud 1500.

FIGS. 17A-C illustrate steps of an example manufacturing processutilized to form the first shroud 1500. Specifically, FIGS. 17A-Cillustrate the steps of the manufacturing process in the context of thefirst shroud 1500 including the first inner shell 1502 of FIG. 15 andthe second inner shell 1600 of FIG. 16 . In FIG. 17A, the inner shell1502, 1600 is formed. For example, the inner shell 1502, 1600 can beformed via molding, thermal spraying, and/or cold spraying. In FIG. 17B,the core shell 1506 is electroformed on in the inner shell 1502, 1600.In FIG. 17C, the outer shell 1504 is thermal sprayed or cold sprayed onthe core shell 1506.

FIG. 18 is a flowchart representative of an example method 1800 tomanufacture a barrier can, such as the shroud 1500 of FIGS. 15 and/or17C. In some examples, at least a portion of the example method 1800 isrepresentative of example machine readable instructions that may beexecuted and/or instantiated by processor circuitry in communicationwith manufacturing equipment to manufacture the shroud 1500.

Additionally or alternatively, the method 1800 of FIG. 18 may utilize anApplication Specific Integrated Circuit (ASIC) and/or a FieldProgrammable Gate Array (FPGA) structured to cause operationscorresponding to the method 1800 to be performed by manufacturingequipment.

The example method 1800 of FIG. 18 begins at block 1802, at which theinner shell 1502, 1600 is formed. For example, the inner shell 1502,1600 can be formed via molding and/or slurry-based manufacturingtechniques, such as additive manufacturing (e.g., thermal spraying orcold spraying) and/or sintering.

At block 1804, the core shell 1506 is formed on the inner shell 1502,1600. For example, the core shell 1506 can be electroformed on an outersurface of the inner shell 1502, 1600. Accordingly, the inner shell1502, 1600 serves as a mandrel for the electroforming of the core shell1506. As a result, an inner surface of the core shell 1506 is fully incontact with the inner shell 1502, 1600.

At block 1806, the outer shell 1504 is formed on the core shell 1506.For example, the outer shell 1504 can be thermal sprayed and/or coldsprayed on the core shell 1506. In some examples, the outer shell 1504is thermal sprayed and/or cold sprayed on a portion (e.g., an edge) ofthe inner shell 1502 such that the outer shell 1504 and the inner shell1502 encapsulate the core shell 1506. As a result, an outer surface ofthe core shell 1506 is fully in contact with the outer shell 1504.

In some examples, the shroud 1500 includes first means for insulating.For example, the first means for insulating may be implemented by theinner shell 1502 of FIGS. 15 and 17A-C or the inner shell 1600 of FIGS.16 and 17A-C. In some examples, the first means for insulating mayinclude a ceramic, a polymer, or a composite. For instance, the firstmeans for insulating may include aluminum(I) oxide (Al₂O), aluminum(II)oxide (AlO) (e.g., aluminum monoxide), aluminum(III) oxide (Al₂O₃)(e.g., aluminum oxide, alumina), zirconia (e.g., zirconia toughenedalumina), and/or silicon carbide.

In some examples, the shroud 1500 includes second means for insulating.For example, the second means for insulating may be implemented by theouter shell 1504 of FIGS. 15 and 17A-C. In some examples, the secondmeans for insulating may include a ceramic, a polymer, or a composite.For instance, the first means for insulating may include aluminum(I)oxide (Al₂O), aluminum(II) oxide (AlO) (e.g., aluminum monoxide),aluminum(III) oxide (Al₂O₃) (e.g., aluminum oxide, alumina), zirconia(e.g., zirconia toughened alumina), and/or silicon carbide.

In some examples, the shroud 1500 includes means for supporting thefirst means for insulating and the second means for insulating. Themeans for supporting can fill an area defined between the first meansfor insulating and the second means for insulating. For example, themeans for supporting may be implemented by the core shell 1506. In someexamples, the means for supporting includes nickel, cobalt, and/or oneor more other metals.

In some examples, the shroud 1500 includes means for stiffening. Forexample, the means for stiffening can be implemented by the ribs 1604 inthe inner shell 1600 of FIGS. 16 and 17A-17C and/or the core shell 1506positioned around the ribs 1604.

Example layered magnetic coupling shrouds or barrier cans are disclosedherein. The example layered magnetic coupling shrouds or barrier canscan include an inner shell, an outer shell, and a metal core shellbetween the inner shell and the outer shell. The inner shell or theouter shell can serve as a mandrel upon which the metal core shell isformed. Electroforming the metal core shell enables the metal core shellto a reduced thickness (e.g., as small as 2 mils) compared to othermanufacturing techniques. In turn, the metal core shell can cause lesseddy current loss between magnetic couplings positioned within andaround the layered shroud or barrier can while providing structuralsupport that can withstand higher pressures (e.g., pressures greaterthan 6,400 PSI). Furthermore, the inner shell and the outer shell caninsulate the metal core shell from the fluid to prevent the metal coreshell from encountering oxidation and/or being affected by certainextreme temperatures. Moreover, the inner shell and/or the outer shellcan be formed via thermal spraying and/or cold spraying to furtherreduce a thickness of the barrier can and, thus, enable the barrier canor shroud to cause less eddy current loss and/or enable a size of themagnetic couplings to be reduced.

High Pressure Magnetic Coupling Shroud and Methods of Producing the Same

FIG. 19 illustrates another example shroud 1900 (e.g., a barrier can)that can be utilized in the thermal transport bus pump 400 (e.g., thebarrier can 452 of FIG. 4 ), the pump system 500 of FIG. 5 (e.g., thebarrier can 536 of FIG. 5 ), the pump system 600 of FIG. 6 (e.g., thebarrier can 636 of FIG. 6 ), the pump system 700 of FIG. 7 (e.g., thebarrier can 728 of FIG. 7 ), and/or any other pump systems disclosedherein that utilize a barrier can or shroud to contain a flow of fluid.In the illustrated example of FIG. 19 , the shroud 1900 includes anouter shell 1902 (e.g., an outer layer) and an inner shell 1904 (e.g., aliner) fixed to the outer shell 1902.

In FIG. 19 , a thickness of the outer shell 1902 is between 25 mils and150 mils. The outer shell 1902 includes a composite material to providestructural strength and withstand a pressure encountered by the shroud1900. The composite material can include carbon fibers, graphite fibers,and/or an epoxy resin. The epoxy resin can bind the fibers in a certainposition and/or orientation to increase the structural strength of theouter shell 1902. In turn, the outer shell 1902 can provide thestructural strength of a metallic material at a reduced weight.Moreover, utilizing the composite material in the outer shell 1902 asopposed to a metal improves (e.g., reduces) an eddy current lossencountered between the first magnetic coupling 450 and the secondmagnetic coupling 460. Advantageously, the reduced eddy current lossthat results from utilizing the outer shell 1902 increases a maximumspeed at which the magnetic couplings 450, 460 can operate whileremaining rotationally interlocked and improves an efficiency with whichtorque is transferred between the first magnetic coupling 450. Further,the reduced eddy current loss enables a size of the first magneticcoupling 450, the second magnetic coupling 460, and/or the motor 410 ofFIG. 4 to be reduced. Additionally, the reduced eddy current lossprevents a need for a cooling sleeve around the coupling housing 424 asthermal energy generated by rotation of the first magnetic coupling 450and the second magnetic coupling 460 is reduced.

In FIG. 19 , the carbon fibers and/or the graphite fibers are positionedin more than one orientation, as discussed in further detail below. Forexample, the fibers can be positioned in a first orientation, a secondorientation different from the first orientation, a third orientationdifferent from the first orientation and the second orientation, and afourth orientation different from the first orientation, the secondorientation, and the third orientation. In some examples, the firstorientation is in an axial direction A defined by the shroud 1900 andthe second orientation is in a circumferential direction C defined bythe shroud 1900. Accordingly, the first orientation is substantiallyorthogonal to the second orientation. The third orientation can beapproximately 45° from the first orientation and the second orientationin a first direction. The fourth orientation can be approximately 45°from the first orientation and the second orientation in a seconddirection substantially orthogonal to the first direction. Accordingly,the third orientation is substantially orthogonal to the fourthorientation.

In the illustrated example of FIG. 19 , the composite material thatforms the outer shell 1902 is porous. As such, the inner shell 1904covers an inner surface of the outer shell 1902 to prevent fluid fromescaping through pores of the outer shell 1902 and, in turn, enable theshroud 1900 to hermetically seal the forward bearing housing 428 andprevent the fluid from becoming contaminated. A thickness of the innershell 1904 can be as small as 2 mils. The inner shell 1904 includes athermoplastic composite and/or a metallic material. In some examples,the inner shell 1904 includes Torlon®. Advantageously, temperature andstructural strength properties associated with Torlon® enable the shroud1900 of 6,400 PSIA when the inner shell 1904 is only 5 mils thick.Additionally, given that Torlon® does not include a metallic material,the Torlon® enables the inner shell 1904 to minimize or otherwise reducean eddy current loss caused by the shroud 1900. In some examples, theinner shell 1904 includes a thermoplastic composite other than Torlon®,such as polyetheretherketone (PEEK). In some examples, the inner shell1904 includes a nickel based alloy to maximize or otherwise increase apressure that the shroud 1900 is able to withstand. For example, theinner shell 1904 can include a nickel-chromium based alloy, such as anickel-chromium-molybdenum alloy (e.g., INCO718).

In FIG. 19 , the outer shell 1902 is formed via a composite lay-upprocess. For example, the composite lay-up process can include layingcomposite layers ply by ply such that a first composite ply of the outershell 1902 is formed on a second composite ply, which is formed on athird composite ply, etc. Accordingly, the composite layers includecarbon fibers and/or graphite fibers in an epoxy resin. The carbonfibers and/or the graphite fibers are layered in certain positionsand/or orientations with the epoxy resin and, in turn, thermosetting canbe utilized to enable the epoxy resin to bind the fibers in place.Specifically, the fibers are layered on top of each other in the firstorientation, the second orientation, the third orientation, and thefourth orientation. For example, a first set of fibers can be set in thefirst orientation, a second set of fibers can be set on top of the firstset of fibers (e.g., around a circumference defined by the first set offibers) in the second orientation, a third set of fibers can be set ontop of the second set of fibers in the third orientation, and a fourthset of the fibers can be set on top of the third set of fibers in thefourth orientation. Moreover, layers of the first, second, third, andfourth set of fibers can be stacked such that the fibers define acertain thickness. For example, the thickness can be based on a pressureat which an associated pump (e.g., the thermal transport bus pump 400 ofFIG. 4 ) is to operate. Additionally, the sets of fibers can be stackedin another arrangement or in multiple arrangements. For example, theouter shell 1902 can include the third set of fibers stacked on thefirst set of fibers, the second set of fibers stacked on the third setof fibers, and the fourth set of fibers stacked on the second set offibers. Further, a first group of the sets of fibers can be stacked in adifferent arrangement from a second group of the sets of fibers that ispositioned around the first group. Additionally, the inner shell 1904can include short fibers for structural reinforcement.

Accordingly, the outer shell 1902 can be formed via the composite lay-upprocess such that the outer shell 1902 includes a first thickness. Insome examples, an inner surface 1905 of the outer shell 1902 can bemachined down to cause the outer shell 1902 to have a second thicknessthat provides room for the inner shell 1904 while maintaining the shroud1900 within a certain thickness range. In some examples, a thickness ofthe outer shell 1902 can be up to 0.125 in.

In FIG. 19 , when the inner shell 1904 is to include the nickel basedalloy, the inner shell 1904 is formed on the inner surface 1905 of theouter shell 1902 via electroforming. When the inner shell 1904 is toinclude the Torlon® or another thermoplastic composite (e.g., PEEK), theinner shell 1904 can be formed via machining rods of the Torlon® orPEEK, for example. In turn, the outer shell 1902 can be layered on anouter surface 1907 of the inner shell 1904. In some examples, a flangeportion 1906 of the shroud 1900 is formed completely via the outer shell1902.

FIGS. 20A-D illustrate example orientations of the fibers of the outershell 1902 of FIG. 19 . In FIGS. 20A-D, the composite layers can be laidlayer by layer in a direction 2001 normal to the inner shell 1904 ofFIG. 19 and/or an inner composite layer of the outer shell 1902.

FIG. 20A illustrates example first fibers (e.g., a first set of fibers)of the outer shell 1902 positioned in a first orientation 2002, whichextends along a circumferential direction C defined by the shroud 1900of FIG. 19 . Accordingly, ones of the first fibers are wrappedcircumferentially around a cavity defined by the shroud 1900 of FIG. 19. Further, the ones of the first fibers are spaced apart along an axialdirection A defined by the shroud 1900 of FIG. 19 .

FIG. 20B illustrates example second fibers (e.g., a second set offibers) of the outer shell 1902 positioned in a second orientation 2004,which extends along the axial direction A defined by the shroud 1900 ofFIG. 19 . Accordingly, the second fibers extend in the axial direction Aand wrap around an aft end of the cavity defined by the shroud 1900 ofFIG. 19 . In other words, the second fibers wrap around the cavity in aU-shape. As such, the second orientation 2004 is substantiallyorthogonal to the first orientation 2002. Moreover, ones of the secondfibers are spaced apart along the circumferential direction C defined bythe shroud 1900. Accordingly, respective ends of ones of the secondfibers are positioned directly opposite each other (e.g., 180° from eachother) across the cavity of the shroud 1900.

FIG. 20C illustrates example third fibers (e.g., a third set of fibers)of the outer shell 1902 positioned in a third orientation 2006, whichextends approximately 45° between the first orientation 2002 and thesecond orientation 2004 in a first direction. Accordingly, the thirdfibers extend in both the axial direction A and the circumferentialdirection C defined by the shroud 1900 of FIG. 19 . In other words, thethird fibers wrap around the cavity defined by the shroud 1900 of FIG.19 in an oblong shape. Moreover, ones of the third fibers are spacedapart along the axial direction A defined by the shroud 1900 of FIG. 19.

FIG. 20D illustrates example fourth fibers (e.g., a fourth set offibers) of the outer shell 1902 positioned in a fourth orientation 2008,which extends approximately 45° between the first orientation and thesecond orientation in a second direction. Specifically, the fourthorientation 2008 is substantially orthogonal to the third orientation2006. That is, the fourth orientation 2008 extends in both the axialdirection A and the circumferential direction C defined by the shroud1900 of FIG. 19 . Accordingly, the fourth fibers wrap around the cavitydefined by the shroud 1900 of FIG. 19 in an oblong shape. Moreover, onesof the fourth fibers are spaced apart along the axial direction Adefined by the shroud 1900 of FIG. 19 .

FIG. 21 illustrates an example overlay of the carbon and/or graphitefibers positioned in the first orientation 2002, the second orientation2004, the third orientation 2006, and the fourth orientation 2008 in aportion 1908 of the outer shell 1902, as identified in FIG. 19 . In FIG.21 , the outer shell 1902 includes first fibers 2102 in the firstorientation 2002, second fibers 2104 in the second orientation 2004,third fibers 2106 in the third orientation 2006, and fourth fibers 2108in the fourth orientation 2008. Specifically, the first fibers 2102extend in the circumferential direction C around the cavity defined bythe shroud 1900 of FIG. 19 . Further, the second fibers 2104 extendsubstantially orthogonal to the first fibers 2102 in the axial directionA defined by the shroud 1900 of FIG. 19 . The third fibers 2106 extendapproximately 45° between the first fibers 2102 and the second fibers2104. Moreover, the fourth fibers 2108 extend substantially orthogonalto the third fibers 2106.

FIG. 22A is a flowchart representative of a first example method 2200 tomanufacture a barrier can, such as the shroud 1900 of FIG. 19 . In someexamples, at least a portion of the example method 2200 isrepresentative of example machine readable instructions that may beexecuted and/or instantiated by processor circuitry in communicationwith manufacturing equipment to manufacture the shroud 1900.Additionally or alternatively, the method 2200 of FIG. 22A may utilizean Application Specific Integrated Circuit (ASIC) and/or a FieldProgrammable Gate Array (FPGA) structured to cause manufacturingoperations corresponding to the method 2200 to be performed bymanufacturing equipment.

The example method 2200 of FIG. 22A begins at block 2202, at which theouter shell 1902 (FIGS. 19-21 ) is formed. For example, the outer shell1902 can be formed via a composite lay-up process and/or a thermosettingprocess. Specifically, the first fibers 2102 (FIG. 21 ) are positionedin the first orientation 2002 (FIGS. 20A and 21 ), the second fibers2104 (FIG. 21 ) are positioned in the second orientation 2004 (FIGS. 20Band 21 ) substantially orthogonal to the first orientation 2002, thethird fibers 2106 (FIG. 21 ) are positioned in the third orientation2006 (FIGS. 20C and 21 ), and the fourth fibers 2108 (FIG. 21 ) arepositioned in the fourth orientation 2008 (FIGS. 20D and 21 ) in anepoxy resin. Further, the first fibers 2102, the second fibers 2104, thethird fibers 2106, and the fourth fibers 2108 can alternate inrespective layers. In turn, the layers define a thickness of the outershell 1902. In some examples, the respective layers of the fibers 2102,2104, 2106, 2108 can be thermoset such that the epoxy resin holds thefibers 2102, 2104, 2106, 2108 in the respective orientations 2002, 2004,2006, 2008.

At block 2204, an inner surface of the outer shell 1902 is machined. Forexample, the inner surface of the outer shell 1902 can be grinded ormachined such that a thickness of the outer shell 1902 is reduced.Accordingly, machining the outer shell 1902 to the reduced thickness canprovide space for the inner shell 1904 (FIG. 19 ) such that the secondmagnetic coupling 460 does not contact the inner shell 1904.

At block 2206, the inner shell 1904 is formed on the inner surface ofthe outer shell 1902. For example, when the inner shell 1904 includes ametallic material, the inner shell 1904 can be formed on the innersurface of the outer shell 1902 via electroforming. Further, when theinner shell 1904 includes a thermoplastic composite, such as Torlon®and/or PEEK, the inner shell 1904 can be formed on the inner surface ofthe outer shell 1902 via additive manufacturing. Accordingly, formingthe inner shell 1904 via additive manufacturing or electroformingenables the inner shell 1904 to be formed with a reduced thickness thatprovides space for the second magnetic coupling 460 in the cavitydefined by the shroud 1900 (FIG. 19 ) while sealing the inner surface ofthe outer shell 1902.

FIG. 22B is a flowchart representative of a second example method 2250to manufacture a barrier can, such as the shroud 1900 of FIG. 19 . Insome examples, at least a portion of the example method 2250 isrepresentative of example machine readable instructions that may beexecuted and/or instantiated by processor circuitry in communicationwith manufacturing equipment to manufacture the shroud 1900.Additionally or alternatively, the method 2250 of FIG. 22B may utilizean Application Specific Integrated Circuit (ASIC) and/or a FieldProgrammable Gate Array (FPGA) structured to cause manufacturingoperations corresponding to the method 2250 to be performed bymanufacturing equipment.

The example method 2250 of FIG. 22B begins at block 2252, at which theinner shell 1904 (FIG. 19 ) is formed. For example, the inner shell 1904can be machined from rods of Torlon® or another thermoplastic composite(e.g., PEEK). In some examples, when the inner shell 1904 includes ametallic material, the inner shell 1904 is electroformed on a mandreland subsequently separated from the mandrel.

At block 2254, the outer shell 1902 (FIGS. 19-21 ) is layered on theinner shell 1904. For example, the outer shell 1902 can be formed via acomposite lay-up process. Specifically, a first layer of the outer shell1902 including at least one set of the fibers 2102, 2104, 2106, 2108 canbe layered on the outer surface 1907 (FIG. 19 ) of the inner shell 1904.Further, a second layer of the outer shell 1902 including at least oneset of the fibers 2102, 2104, 2106, 2108 can be layered on the firstlayer. In some examples, the first layer is thermoset in advance of thesecond layer being applied. Accordingly, the outer shell 1902 is formedin layers on the inner shell 1904.

Example layered magnetic coupling shrouds or barrier cans are disclosedherein. The example layered magnetic coupling shrouds or barrier canscan include an outer shell to provide structural support than canwithstand higher pressures (e.g., a pressure of at least 6,400 PSI).Furthermore, the example layered magnetic coupling shrouds or barriercans can include an inner shell formed on an inner surface of the outershell to prevent fluid from leaking through pores of the outer shell.Advantageously, no eddy current loss occurs when Torlon® or anotherthermoplastic (e.g., PEEK), is utilized to form the inner shell 1904.Furthermore, when the inner shell includes the metallic material, aratio of the eddy current loss (in kilowatts (kW)) to inner shellthickness (in mils (e.g., thousands of an inch)) can be less than 0.06.As a result, the example layered magnetic coupling shrouds and/orbarrier cans enable magnetic couplings to remain magnetically engagedand, in turn, rotationally interlocked at higher angular velocities.Accordingly, the example layered magnetic coupling shrouds or barriercans enable an impeller in an associated pump to be driven with a higherangular velocity to increase a pressure and/or flow rate of a fluid(e.g., a heat exchange fluid such as a supercritical fluid (e.g., sCO₂,etc.)) and, thus, enable the fluid to transfer more thermal energy toand/or from a working fluid in an associated aircraft and/or engine.

Oil Lubricated Supercritical Fluid Pump with Oil Separator

As mentioned above, in order for thermal energy to be transferredbetween the fluid (e.g., a heat exchange fluid such as a supercriticalfluid (e.g., sCO₂, etc.)) and a working fluid without negativelyimpacting components of the aircraft 10 and/or the gas turbine engine100, the fluid should be free of contamination with foreign substancesin areas where the fluid is to transfer thermal energy. That is, thefluid should not be contaminated with oil, water (e.g., vapor), and/orambient air when passing through the heat source heat exchangers 206 andthe heat sink heat exchangers 208 of FIG. 2 .

As discussed above, the rolling element bearings 440, 448 that supportthe shaft 438 of the motor 410 require an oil lubrication that is notthe fluid. In turn, the barrier can 452 of FIG. 4 separates the fluidfrom the motor housing 412 to prevent the fluid from becomingcontaminated by the oil lubrication of the rolling element bearings 440,448 in the pump 400. However, utilizing separate housings, such as themotor housing 412, the aft bearing housing 418, the intermediate bearinghousing 420, and the coupling housing 424 and, increases a size, aweight, and/or a cost of the pump 400. Moreover, driving a rotation ofthe impeller 406 via the magnetic couplings 450, 460 may result in aneddy current loss that limits a rotational velocity with which themagnetic couplings 450, 460 can drive the impeller 406.

Example oil separators that enable the fluid to mix with oil andsubsequently be separated from the oil are disclosed herein.Accordingly, the example oil separators enable the fluid to flow througha housing that includes oil lubricated bearings to mount a motor shaft(e.g., the shaft 438 of FIG. 4 ). As a result, the oil separators enablea size, a weight, and/or a cost of the pump 204 of FIG. 3 to be reduced.Additionally, the oil separators can enable a quantity of components inthe pump 204 to be reduced. For example, by enabling the fluid to mixwith oil, the oil separators remove a need for a barrier can (e.g., thebarrier can 452 of FIG. 4 ), magnetic couplings (e.g., the magneticcouplings 450, 460 of FIG. 4 ), and/or distinct housings to hold oillubricated parts separate from the fluid. Further, the example oilseparators enable the pump 204 to drive an impeller without magneticcouplings, which increases a rotational velocity at which the impellercan operate and, thus, increases a maximum pressure and/or flow ratewith which the pump 204 can drive the fluid through the thermaltransport bus 202.

Specifically, an example pump system to pressurize a fluid (e.g., a heatexchange fluid such as a supercritical fluid (e.g., sCO₂, etc.)) withina closed loop transport bus (e.g., the thermal transport bus 202)includes a pump housing and a duct fluidly coupled to the pump housing.During an operation of the example pump system, a first portion of theduct includes a mixture of an oil and a supercritical fluid (e.g.,supercritical carbon dioxide) and a second portion of the duct includesthe supercritical fluid by itself. Accordingly, a separator (e.g., anoil separator) is positioned in a third portion of the duct between thefirst portion of the duct and the second portion of the duct such thatthe separator can separate the oil in the mixture from the supercriticalfluid. Accordingly, the separator enables the supercritical fluid toflow within the pump housing and mix with oil from lubricated bearingsthat, for example, mount and/or support a shaft of a motor that drivesan impeller.

In some examples, the pump system includes more than one separator. Theexample separators can be static (e.g., stationary) or dynamic (e.g.,moveable, rotatable, etc.). In some examples, a dynamic or rotatableseparator includes a rotatable shaft and vanes or ridges extendingradially outward from the rotatable shaft. In some examples, therotatable separator includes a conical casing that is rotatable. In somesuch examples, the conical casing includes open axial ends and aperturesfacing a surrounding duct. In some examples, the conical casing ispositioned around the rotatable shaft. In some such examples, therotatable shaft can rotate in a first direction and the conical casingcan be stationary or rotate in a second direction opposite the firstdirection.

Accordingly, when the vanes and/or conical casing rotate, oil moleculesin the mixture experience more centrifugal force than particles of thesupercritical fluid because of the higher density of oil compared to thesupercritical fluid. In turn, the greater centrifugal force encounteredby the oil causes the oil particles to stick to an inner surface of thecasing, to stick to the surrounding duct, to be driven through theapertures in the casing, and/or to be driven through an oilrecirculating flow path that guides the oil back to the pump 204 or anoil storage supply (e.g., an oil tank). Furthermore, the reducedcentrifugal force encountered by the supercritical fluid particlesenables the supercritical fluid to flow in a middle portion of the ductand/or through the conical casing as the oil is driven radially outward.

In some examples, a static or stationary separator includes an oilabsorbent material. For example, the oil absorbent material can includea polymer (e.g., polyurethane, polypropylene, polyethylene, cross-linkedpolymers, etc.) and/or a powder (e.g., talc, aluminum starch, ricestarch, silica, etc.). In some examples, the stationary separatorincludes baffles that eliminate or otherwise reduce any straight lineflow path for the supercritical fluid through the third portion of theduct. Specifically, the baffles include the oil absorbent material. As aresult, the baffles cause the oil particles that are mixed with thesupercritical fluid to contact the stationary separator and, in turn, beabsorbed by the oil absorbent material. Accordingly, the stationaryseparator serves as a filter that collects the oil and allows thesupercritical fluid to pass therethrough. Further, the higher density ofoil and the pressure of the fluid flowing through the stationaryseparator can cause the oil to fall through pores (e.g., channels ofpores) in the baffles such that the oil particles enter the oilrecirculating flow path.

The baffles can be formed in various shapes with different thicknessesand/or porosities to enable a pressure drop encountered by thesupercritical fluid in the third portion of the duct to be controlled.In some examples, a structure of the baffles can be formed with sheetmetals and/or via additive manufacturing. The example stationaryseparator can be disposed horizontally or vertically in the thirdportion of the duct.

In some examples, the static oil separator includes a first duct (e.g.,a main duct) fluidly coupled to a second duct (e.g., an oil collectionduct) positioned underneath the first duct. In some examples, the secondduct is fluidly coupled to the first duct at multiple distinctlocations. Because of the higher density of oil compared to thesupercritical fluid, the oil can fall from the first duct and enter thesecond duct. Further, the first duct can include baffles that cause themixture of supercritical fluid and oil to flow with a downward velocitywhen the mixture encounters a point at which the first duct is fluidlycoupled to the second duct. In turn, the downward velocity and thehigher density of the oil can cause the oil particles to fall out of thefirst duct and into the second duct. Further, the baffles formed by thefirst duct can cause the mixture to flow upwards towards the end of theconnection between the ducts such that the first duct causes the fluidsin the mixture to change from the downward velocity to an upwardvelocity. Accordingly, the change from the downward velocity to theupward velocity is easier for the supercritical fluid because of thelower density of the supercritical fluid. As a result, a composition ofthe oil in the first duct is reduced at each connection point thatfluidly couples the first duct to the second duct. In turn, the oil canbe completely separated from the supercritical fluid in the first ductat or before a last connection point between the ducts. Moreover, thesecond duct can form or be fluidly coupled to the oil recirculating flowpath.

FIG. 23 illustrates an example pump system 2300 including a firstexample separator 2302 (e.g., a first stationary separator, a barrelfilter, etc.) to separate a supercritical fluid (e.g., supercriticalcarbon dioxide) from oil in a duct 2304 (e.g., a discharge duct) throughwhich the supercritical fluid is driven (e.g., prior to entering thethermal transport bus 202 of FIG. 2 or within the thermal transport bus202 prior to the heat exchangers 206, 208). In the illustrated exampleof FIG. 23 , the pump system 2300 includes a pump housing 2306.Specifically, the pump housing 2306 is formed by a motor housing 2308, abackplate 2310, and a compressor collector 2312 coupled together viabolts 2314. The pump housing 2306 further includes a cap 2316 fixedlycoupled to an aft end of the motor housing 2308 via bolts 2318. The pumphousing 2306 is fluidly coupled to the duct 2304 such that fluid canflow through the motor housing 2308, the backplate 2310, the compressorcollector 2312, and the duct 2304.

In the illustrated example of FIG. 23 , the pump system 2300 includes amotor 2320 positioned in the motor housing 2308. In FIG. 23 , a rotor2322 of the motor 2320 is fixed to a shaft 2324 (e.g., a motor shaft).Accordingly, the motor 2320 drives a rotation of the shaft 2324. Thepump system 2300 further includes a cooling jacket 2315 wrapped aroundthe motor housing 2308 to prevent the motor 2320 from overheating.

The shaft 2324 is supported by a first rolling element bearing 2325(e.g., an aft rolling element bearing) and a second rolling elementbearing 2327 (e.g., a forward rolling element bearing) both of which arelubricated with oil. In the illustrated example of FIG. 23 , the oillubricating the first rolling element bearing 2325 and the secondrolling element bearing 2327 is mixed with an additive. Specifically,the additive increases a viscosity of the oil and, thus, improvescohesion and adhesion properties associated with the oil.

In the illustrated example of FIG. 23 , an aft end of the shaft 2324extends past an aft end of the motor housing 2308. Accordingly, the cap2316 includes an indent or a cavity 2317 in which the aft end of theshaft 2324 is disposed. The first rolling element bearing 2325 ispositioned in a bearing cup 2326 disposed in the motor housing 2308.Specifically, the bearing cup 2326 can be press fitted in the bearingcup 2326 and supported by shoulders 2328 of the motor housing 2308. Tohelp interlock the first rolling element bearing 2325 on the shaft 2324,the first rolling element bearing 2325 includes a collar clamp 2330 thatextends from an aft side of the first rolling element bearing 2325 andclamps around the shaft 2324. Additionally, a preloaded spring 2332 ispositioned between the bearing cup 2326 and a forward side of the firstrolling element bearing 2325 to help maintain a position of the firstrolling element bearing 2325 within the bearing cup 2326. Furthermore, asub-cap 2334 is coupled to an aft end of the bearing cup 2326 via screws2336. Accordingly, the sub-cap 2334 includes an orifice through whichthe shaft 2324 extends.

The second rolling element bearing 2327 is press fitted in the backplate2310. To maintain a position of the second rolling element bearing 2327on the shaft 2324, the second rolling element bearing 2327 includes acollar clamp 2337 that extends from a forward side of the second rollingelement bearing 2327 and clamps around the shaft 2324. An aft end of thesecond rolling element bearing 2327 is positioned against shoulders 2338of the backplate 2310 and ridges 2339 in the shaft 2324.

In the illustrated example of FIG. 23 , an impeller 2340 is coupled to aforward end of the shaft 2324 such that the impeller 2340 rotates withthe shaft 2324 to pump fluid through the duct 2304. Specifically, tocouple the impeller 2340 to the shaft 2324, a portion of an aft end ofthe impeller 2340 is wedged in, and fixed to, an internal slot of theshaft 2324. Alternatively, the aft end of the impeller 2340 can includea slot and the shaft 2324 can extend into the slot of the impeller 2340to rotatably couple the shaft 2324 and the impeller 2340. Additionally,the aft end of the impeller 2340 is coupled to a support plate 2342. Insome examples, the support plate 2342 screws onto the shaft 2324 tofurther increase a strength of the coupling between the impeller 2340and the shaft 2324.

Accordingly, both the impeller 2340 and the rotor 2322 of the motor 2320are mounted on the shaft 2324. As a result, a size of the pump system2300 and/or a quantity of components utilized to drive the impeller 2340are minimized or otherwise reduced. Furthermore, an output of the pumpsystem 2300 (e.g., an output pressure and/or flow rate of the fluidexiting the pump system 2300) can be increased as the rotation of theimpeller 2340 is independent of magnetic couplings that encounterincreased eddy current loss at higher rotational speeds.

During operation, the supercritical fluid (e.g., sCO₂, etc.) flowsthrough an inlet 2344 of the pump system 2300 and is driven by theimpeller 2340. Specifically, the impeller 2340 drives the supercriticalfluid toward the duct 2304. As the supercritical fluid encounters higherpressures, a portion of the supercritical fluid escapes into the motorhousing 2308. For example, the supercritical fluid can flow between thesupport plate 2342 and the backplate 2310. In turn, the supercriticalfluid can pass through the second rolling element bearing 2327 where thesupercritical fluid mixes with oil lubricating the second rollingelement bearing 2327 before dispersing throughout the motor housing2308. Accordingly, the supercritical fluid can further mix with oillubricating the first rolling element bearing 2325. As a result, amixture of the supercritical fluid and the oil is formed in the motorhousing 2308. Moreover, as supercritical fluid continues to flow intothe motor housing 2308, pressure builds up and the mixture is pushedback into the compressor collector 2312. In some examples, the mixtureflows through a slot 2345 in the shaft 2324, which aligns with a slot2346 in the impeller 2340 to enable the mixture to flow into thecompressor collector 2312 and be driven into the duct 2304 by theimpeller 2340. Additionally or alternatively, the mixture can flow intothe compressor collector 2312 between the support plate 2342 and thebackplate 2310.

In FIG. 23 , in response to being pumped into the duct 2304, the mixtureof the supercritical fluid and the oil encounters the first separator2302. In FIG. 23 , the separator 2302 is a barrel filter including aninner cylinder 2347 and an outer cylinder 2348. Specifically, the firstseparator 2302 includes interconnected concentric cylinders 2347, 2348formed at least partially by an oil absorbent material. In someexamples, the oil absorbent material includes at least one powder, suchas talc, aluminum starch, rice starch, silica, etc. In some examples,the oil absorbent material includes at least one polymer, such aspolyurethane, polypropylene, polyethylene, cross-linked polymers, etc.The inner cylinder 2347 and the outer cylinder 2348 can include bafflesto increase a rate at which oil in the mixture contacts a surface of theseparator 2302. The separator 2302 is manufactured via forming of sheetmetals and/or additive manufacturing, for example.

In some examples, the separator 2302 includes a first conduit and asecond conduit. For example, the first conduit can be positioned aboveand fluidly coupled to the second fluid conduit. Moreover, the firstfluid conduit can include baffles and the second fluid conduit caninclude the oil absorbent material, as discussed in further detailbelow.

In some examples, the first separator 2302 includes separate cylindricalfilters positioned in series or in parallel in the duct 2304. Forexample, the first separator 2302 can include a first cylindrical filterpositioned above a second cylindrical filter.

As the mixture of the supercritical fluid and the oil flows through theseparator 2302, the separator 2302 absorbs the oil. As a result, theduct 2304 only carries the supercritical fluid into the thermaltransport bus 202. In FIG. 1 , an aft end of the separator 2302 ispositioned against a plate 2350. Specifically, the plate 2350 includesgrooves in which the separator 2302 is positioned. Further, the plate2350 is coupled to an exterior of the motor housing 2308 via one or morebolts 2352. Additionally or alternatively, the plate 2350 can be coupledto the duct 2304. When an operation of the pump system 2300 is stoppedor paused, the plate 2350 can be removed to allow the separator 2302 tobe cleaned and/or replaced.

Furthermore, the oil that is separated from the supercritical fluid bythe first separator 2302 can fall into a secondary duct 2354 (e.g., anoil collection duct) positioned below the first separator 2302. Thesecondary duct 2354 is in fluid connection with an inlet 2356 in themotor housing 2308. Accordingly, the oil can be returned to the motorhousing 2308 to provide lubrication for the first and second rollingelement bearings 2325, 2327.

As a result, the first separator 2302 enables the supercritical fluid tomix with oil without impacting the thermal energy transfer capabilitiesof the supercritical fluid. In turn, a quantity of components in thepump system 2300, a size of the pump system 2300, and/or a cost of thepump system 2300 can be minimized or otherwise reduced. Furthermore, thefirst separator 2302 enables the motor 2320 to directly drive theimpeller 2340 via the shaft 2324, which can enable the impeller 2340 tooperate at higher rotational velocities and, thus, increase a pressureand/or a flow rate with which the supercritical fluid is driven throughthe thermal transport bus 202. Accordingly, the first separator 2302 canincrease a rate at which the supercritical fluid is to be transportedthrough the thermal transport bus and, in turn, increase a rate atthermal energy is transferred between the supercritical fluid and theworking fluid.

FIG. 24 illustrates another example pump system 2400 including a secondexample separator 2402 (e.g., a second stationary separator, a conefilter, etc.). In FIG. 24 , the second separator 2402 includes the oilabsorbent material formed in a conical geometry instead of thecylindrical geometry of the first separator 2302 of FIG. 23 . The secondseparator 2402 can be positioned horizontally or vertically in the duct2304 depending on a position of the thermal transport bus 202 relativeto the duct 2304. In FIG. 2 , to maintain a position of the secondseparator 2402, a flange 2404 of the second separator 2402 is pressfitted into the duct 2304. Alternatively, the second separator 2402 canbe coupled to the duct 2304 via screws and/or any other means forcoupling.

In FIG. 24 , in response to the supercritical fluid and the oillubricating the first and second rolling element bearings 2325, 2327mixing in the motor housing 2308, the impeller 2340 drives the mixturethrough the second separator 2402, which absorbs the oil in the mixturewhile enabling the supercritical fluid to pass into the thermaltransport bus 202. As such, the second separator 2402 enables the duct2304 to provide solely the supercritical fluid to the thermal transportbus 202 despite the supercritical fluid being previously contaminatedwith oil from the first and second rolling element bearings 2325, 2327.

Similar to the first example separator 2302 of FIG. 23 , the secondseparator 2402 includes baffles through which the mixture flows.Accordingly, the baffles prevent the mixture from having a straight lineflow path through the second separator 2402 and, thus, ensures that theoil in the mixture contacts the oil absorbent material in the baffles.In some examples, an oil collection duct is positioned below the secondseparator 2402 to enable the oil to be returned to an oil storage supplyand/or the motor housing 2308 via the inlet 2356 in the motor housing2308. Specifically, a density of the oil causes the oil to fall throughthe baffles in the second separator 2402 and into the oil collectionduct, as discussed in further detail below.

FIG. 25 illustrates another example pump system 2500 including thesecond example separator 2402 and a third example separator 2502 (e.g.,a dynamic separator, a rotary separator, a swirler, etc.) positioned inthe duct 2304. In FIG. 25 , the third separator 2502 is positioned inseries with the second separator 2402 in the duct 2304. Specifically,the third separator 2502 is positioned in the duct 2304 upstream of(e.g., forward of) the second separator 2402 and, thus, encounters themixture of the supercritical fluid and the oil in advance of the secondseparator 2402.

In FIG. 25 , the third separator 2502 includes a motor 2504 and aswirler 2506. Further, the swirler 2506 is mounted on a rolling elementbearing 2508 coupled to the duct 2304. In some examples, the rollingelement bearing 2508 includes solid lubricants (e.g., silver coating,graphite, molybdenum disulfide, etc.) to avoid adding oil to themixture. In some examples, the swirler 2506 is mounted via a foilbearing or any other bearing that enables the swirler to rotate withoututilizing a lubricant.

Accordingly, the motor 2504 drives a rotation of the swirler 2506. Inturn, the rotation of the swirler 2506 causes oil droplets in themixture to encounter a centrifugal force. Specifically, the rotation ofthe swirler 2506 causes the oil droplets in the mixture to encounter anincreased centrifugal force compared to the supercritical fluid becauseof the higher density of oil compared to the supercritical fluid.Moreover, the swirler 2506 includes holes or orifices that face aperimeter of the duct 2304, as discussed in further detail below. As aresult, the third separator 2502 causes the oil droplets to move towardsan inner surface of the swirler 2506 and/or the perimeter of the duct2304 while the supercritical fluid remains within a middle portion ofthe duct 2304. In turn, the third separator 2502 can cause the oildroplets to stick to an inner surface of the duct 2304. In someexamples, the oil droplets contact and lubricate the rolling elementbearing 2508. In some examples, the third separator 2502 is implementedin the duct 2304 without the second separator 2402. In such examples,the third separator 2502 causes the oil to be removed from the mixtureby itself.

In FIG. 25 , oil droplets that advance past the third separator 2502 inthe duct 2304 are absorbed by the second separator 2402. Advantageously,a shape of the second separator 2402 provides a greater surface area forthe oil absorbent material towards a perimeter of the duct 2304. Assuch, the higher centrifugal force encountered by the oil dropletsdrives the oil droplets into an outer portion 2510 of the secondseparator 2402, which is larger than a tip portion 2512 of the secondseparator 2402. As a result, the tip portion 2512 remains relativelyunblocked, which reduces an impact of the second separator 2402 on flowproperties of the supercritical fluid as the supercritical fluid entersthe thermal transport bus 202.

FIG. 26 illustrates another example pump system 2600 including thesecond example separator 2402. Additionally or alternatively, the pumpsystem 2600 can include the first separator 1902 and/or the thirdseparator 2502. In FIG. 26 , the pump system 2600 includes a first shaft2602 (e.g., a motor shaft) coupled to the rotor 2322 of the motor 2320.The first shaft 2602 is mounted in the motor housing via the firstrolling element bearing 2325 and a second rolling element bearing 2604(e.g., an intermediate rolling element bearing). In FIG. 26 , the secondrolling element bearing 2604 is positioned in a bearing holder 2606fixed within the motor housing 2308.

Further, the pump system 2600 includes a carrier shaft 2608 coupled to aforward end of the first shaft 2602 that extends past the second rollingelement bearing 2604. Specifically, an aft end of the carrier shaft 2608is concentrically positioned around the forward end of the first shaft2602. The carrier shaft 2608 can be coupled to the first shaft 2602 viaa clamp, a press fit, or any other means for coupling. Further, aforward end of the carrier shaft 2608 extends through a gearbox 2609(e.g., a planetary gearbox). The gearbox 2609 includes the carrier shaft2608, planet gears 2610, a ring gear 2612, and a sun gear 2614, asdiscussed further in association with FIG. 27 .

The carrier shaft 2608 extends radially outward from the first shaft2602 and is rotatably coupled to the planet gears 2610 of the gearbox2609. Accordingly, the carrier shaft 2608 drives a rotation of theplanet gears 2610, which, in turn, causes the sun gear 2614 to rotate.Furthermore, the ring gear 2612 enables the planet gears 2610 totransfer greater torque onto the sun gear 2614. The ring gear 2612 isfixedly positioned in the motor housing 2308. For examples, the ringgear 2612 can be integral with the motor housing 2308 or coupled to themotor housing 2308 via a press fit, screws, or any other means forcoupling.

The sun gear 2614 is defined in an aft end of a second shaft 2616 (e.g.,an impeller shaft) that is coupled to the impeller 2340. In FIG. FIG. 26, the second shaft 2616 is supported by a third rolling element bearing2618 (e.g., a forward rolling element bearing) positioned in thebackplate 2310. For example, the third rolling element bearing 2618 canbe clamped onto the second shaft 2616 and coupled to the backplate 2310via a press fit.

Accordingly, the planet gears 2610 drive a rotation of the impeller2340. As a result, the carrier shaft 2608, the planet gears 2610, thering gear 2612, and the sun gear 2614 provide gear reductions thatenable the impeller 2340 to be driven with a rotational velocity greaterthan that of the first shaft 2602. In turn, the gearbox 2609 enables aflow rate output and/or a pressure output of the pump system 2600 to beincreased to enable improved thermal energy transfer between thesupercritical fluid and the working fluid. Further, the second separator2402, and/or the first separator 2302 and/or the third separator 2502when implemented in the pump system 2600, enables magnetic couplings tobe avoided while still using the rolling element bearings 2325, 2604,2618 and, in turn, enables the gearbox 2609 to provide the gearreductions that cause the impeller 2340 to operate at higher angularvelocities.

FIG. 27 illustrates a cross-section A-A of the gearbox 2609 of FIG. 26 .In FIG. 27 , the carrier shaft 2608 is coupled to the planet gears 2610via respective brackets 2702 and rings 2704 rotatably coupled to aninner circumference of the planet gears 2610. Accordingly, the brackets2702 and the ring 2704 cause the planet gears 2610 to revolve around thesun gear 2614. Furthermore, the planet gears 2610 are able to rotaterelative to the respective rings 2704. Thus, as the carrier shaft 2608causes the planet gears 2610 to revolve around the sun gear 2614, thering gear 2612 causes the planet gears 2610 to rotate relative to therespective rings 2704. In FIG. 27 , the ring gear 2612 is fixedlycoupled to the inner surface of the motor housing 2308 and, thus, doesnot rotate within the motor housing 2308. For example, the ring gear2612 can be fixed within the motor housing 2308 via a press fit, screws,or any other means for coupling.

In some examples, the brackets 2702 and the rings 2704 can be rotatablycoupled to the carrier shaft 2608 and, in turn, be fixedly coupled tothe planet gears 2610. In such examples, the brackets 2702 and the rings2704 rotate with the planet gears 2610 as the carrier shaft 2608 causesthe planet gears 2610 to move around the sun gear 2614.

During operation, the rotor 2322 of the motor 2320 of FIG. 26 drives arotation of the first shaft 2602. Further, the first shaft 2602 drives arotation of the carrier shaft 2608, which causes the planet gears 2610to rotate. In turn, the planet gears 2610 cause the sun gear 2614 torotate. Moreover, the engagement between the planet gears 2610 and thering gear 2612 enables the planet gears 2610 to transfer more torqueonto the sun gear 2614 without encountering slippage. Accordingly, thegearbox 2609 enables the impeller 2340 of FIG. 26 to rotate with agreater velocity as a result of a gear reduction provided by the gearbox2609.

FIG. 28 illustrates another example pump system 2800 including thesecond example separator 2402. Additionally or alternatively, the pumpsystem 2600 can include the first separator 2302 and/or the thirdseparator 2502. In FIG. 28 , the pump system 2800 includes a firstbearing assembly 2802 and a second bearing assembly 2804 to support theshaft 2324 that drives a rotation of the impeller 2340.

The first bearing assembly 2802 is positioned in the bearing cup 2326and, in turn, supports an aft portion of the shaft 2324. The firstbearing assembly 2802 includes a damper 2806 (e.g., a squeeze filmdamper) and a first rolling element bearing 2808 positioned between thedamper 2806 and the shaft 2324. Specifically, the damper 2806 includesan outer race 2810 coupled to the bearing cup 2326. For example, theouter race 2810 can be coupled to the bearing cup 2326 via press fit,screws, and/or any other means for coupling. Further, the damper 2806includes an inner race 2812 and piston rings 2814 positioned between theouter race 2810 and the inner race 2812. Specifically, the piston rings2814 include squeeze film to dampen movements of the inner race 2812relative to the outer race 2810. Furthermore, the inner race 2812defines an outer portion of the first rolling element bearing 2808 thatis coupled to the shaft 2324. Additionally, an inner portion of thefirst rolling element bearing 2808 can be coupled to the shaft 2324 viaa clamp 2813 extending from an aft side of the first rolling elementbearing 2808. Furthermore, the first rolling element bearing 2808 can besupported within the bearing cup 2326 via a preloaded disc spring 2815.

The second bearing assembly 2804 is positioned in a backplate 2817coupled to the motor housing 2308. The second bearing assembly 2804includes spring fingers 2816, a squirrel cage 2818, and a second rollingelement bearing 2820. In FIG. 28 , cylindrical rolling elements of thesquirrel cage 2818 are in contact with and, thus, support the shaft2324. Furthermore, the spring fingers 2816 are coupled to the backplate2817 and a non-rotating portion of the squirrel cage 2818. Accordingly,the spring fingers 2816 provide damping against non-rotational movementsof the shaft 2324. The second rolling element bearing 2820 is positionedaft of the squirrel cage 2818. Specifically, a non-rotating portion ofthe second rolling element bearing 2820 (e.g., an outer portion of thesecond rolling element bearing 2820) is coupled to the non-rotatingportion of the squirrel cage 2818. For example, the squirrel cage 2818can be coupled to the second rolling element bearing 2820 via a pressfit, screws, and/or any other means for coupling.

As a result, the first bearing assembly 2802 and the second bearingassembly 2804 provide damping support for an aft portion of the shaft2324 and a forward portion of the shaft 2324, respectively. Accordingly,the first bearing assembly 2802 and the second bearing assembly 2804reduce vibratory movements of the shaft 2324 that may otherwise arisewhen the rotor 2322 drives the shaft 2324 at higher speeds.

FIG. 29 is a schematic representation of the support provided by thefirst bearing assembly 2802 and the second bearing assembly 2804 of FIG.28 . In FIG. 29 , the first bearing assembly 2802 supports a portion ofthe shaft 2324 disposed aft of the motor 2320 with a first stiffness.Further, the second bearing assembly 2804 supports a portion of theshaft 2324 disposed between the motor 2320 and the impeller 2340 with asecond stiffness less than the first stiffness. Specifically, the firstbearing assembly 2802 provides support with a greater stiffness tostabilize an aft end of the shaft 2324. Further, the second bearingassembly 2804 provides support with less centripetal force against theshaft 2324 to minimize or otherwise reduce a resistance that the secondbearing assembly 2804 causes against a rotational velocity of the shaft2324. Accordingly, the first bearing assembly 2802 may serve as astabilizer while the second bearing assembly 2804 serves as a guide forthe shaft 2324. As such, the first bearing assembly 2802 and the secondbearing assembly 2804 provide support that can dampen non-rotationalmovements of the shaft 2324 while also reducing a resistance against therotational velocity of the shaft 2324.

FIGS. 30A-C illustrate example implementations of rotary separators(e.g., the third separator 2502) that can be implemented in the pumpsystem 2500 of FIG. 25 and/or any other thermal transport pump system.

FIG. 30A illustrates a first example rotary separator 3002 (e.g., afirst swirler, the third separator 2502 of FIG. 25 ) positioned in aduct 3003 (e.g., the duct 2304). In FIG. 30A, the duct 3003 is fluidlycoupled to a secondary duct 3004 that is in connection with an oilsupply, as discussed in further detail below. In FIG. 30A, the firstrotary separator 3002 includes a shaft 3006 and vanes 3008 extendingradially outward from the shaft 3006. During an operation of the firstrotary separator 3002, a motor (e.g., the motor 2504) can drive arotation of the shaft 3006 and the vanes 3008. As a result, the vanes3008 cause oil 3010 (e.g., oil droplets) to encounter an increasedcentrifugal force compared to a supercritical fluid 3012 (e.g.,supercritical carbon dioxide) flowing through the duct 3003.Accordingly, while the first rotary separator 3002 allows thesupercritical fluid 3012 to flow through a middle portion of the duct2304, the rotation of the vanes 3008 causes the oil 3010 to move towardsa perimeter of the duct 3003. Thus, the first rotary separator 3002causes the oil 3010 to separate from the flow of the supercritical fluid3012. Further, the first rotary separator 3002 causes at least a portionof the oil 3010 to move into the secondary duct 3004 where the oil 3010can be collected and/or recirculated to lubricate bearings, such as thefirst and second rolling element bearings 2325, 2327, 2808, 2820 ofFIGS. 23-26 and/or 28 . In some examples, the rotational velocity of thefirst rotary separator 3002 is based on a flow rate(s) within the duct3003 and/or a pressure(s) within the duct 3003.

FIG. 30B illustrates a second example rotary separator 3020 (e.g., asecond swirler, a conical swirler, the third separator 2502 of FIG. 25 ,etc.) positioned in the duct 3003. The second rotary separator 3020 is arotatable cone with holes 3022. Specifically, axial ends of the secondrotary separator 3020 are open to enable the supercritical fluid 3012 toflow through the middle portion of the duct 3003. As the second rotaryseparator 3020 rotates, the higher density of oil compared to thesupercritical fluid 3012 causes the oil 3010 to encounter a greatercentrifugal force than the supercritical fluid 3012. As a result, thesecond rotary separator 3020 removes the oil 3010 from a flow path ofthe supercritical fluid 3012. Specifically, the increased centrifugalforce can cause the oil 3010 to stick to the second rotary separator3020 while the supercritical fluid 3012 flows through the second rotaryseparator 3020. Additionally or alternatively, a swirl velocity createdby the holes 3022 as the second rotary separator 3020 rotates can causethe oil 3010 to flow through the holes 3022 in the second rotaryseparator 3020 and stick to the duct 3003 and/or flow through thesecondary duct 3004 while the supercritical fluid 3012 flows through thesecond rotary separator 3020.

A size and/or a shape of the holes 3022 can be based on flow rates to beencountered in the duct 3003, pressures to be encountered in the duct3003, a rotational velocity of the second rotary separator 3020, aposition of the respective holes 3022 relative to an inner surface ofthe duct 3003, and/or a position of the holes 3022 relative to thesecondary duct 3004. Additionally or alternatively, the rotationalvelocity of the second rotary separator 3020 can be based on the flowrates encountered in the duct 3003 and/or the pressures encountered inthe duct 3003. For example, the size of the holes 3022, the shape of theholes 3022, and/or the rotational velocity of the second rotaryseparator 3020 can increase a likelihood that the centrifugal force andthe swirl velocity encountered by the oil 3010 causes the oil 3010 to bedriven into the secondary duct 3004. Similar to the first rotaryseparator 3002 of FIG. 30A, the second rotary separator 3020 can bedriven by a motor (e.g., the motor 2504).

FIG. 30C illustrates a third example rotary separator 3040 (e.g., athird swirler, the third separator 2502 of FIG. 25 ) positioned in theduct 3003. The third rotary separator 3040 includes a shaft 3042,helical vanes 3044 extending from the shaft 3042, and a conical casing3046 positioned around the shaft 3042. Similar to the second rotaryseparator 3020, the conical casing 3046 includes holes 3048. In FIG.30C, the shaft 3042 and, in turn, the helical vanes 3044 are rotatable.In some examples, the conical casing 3046 is stationary. In someexamples, the conical casing 3046 is rotatable in an opposite directionfrom a rotational direction of the shaft 3042. That is, the shaft 3042can be rotatable in a first direction (e.g., clockwise) and the conicalcasing 3046 can be stationary or rotatable in a second directionopposite the first direction (e.g., counterclockwise).

In FIG. 30C, the rotation of the shaft 3042, the helical vanes 3044,and/or the conical casing 3046 and a density of the oil 3010 relative tothe supercritical fluid 3012 causes the oil 3010 to encounter a firstcentrifugal force greater than a second centrifugal force encountered bythe supercritical fluid 3012. Furthermore, the holes 3048 in the conicalcasing 3046 cause the oil 3010 to encounter a swirl velocity.Accordingly, the swirl velocity can cause the oil 3010 to pass throughthe holes 3048 at a greater velocity and, in turn, stick to the duct3003 with greater force. In some examples, the swirl velocityencountered by the oil 3010 increases a likelihood that the oil 3010enter the secondary duct 3004. For example, the greater velocity of theoil 3010 that results from the swirl velocity can enable the oil 3010 tomove the secondary duct 3004 at a faster rate. Specifically, a size, ashape, and/or a quantity of the holes 3048 can cause the oil 3010 to bedriven on a path directly into the secondary duct 3004. Moreover, theswirl velocity minimizes or otherwise reduces movement of the oil 3010caused by the flow of the supercritical fluid 3012 in the duct 3003.

FIGS. 31A-C illustrate example implementations of static separators(e.g., the first separator 2302, the second separator 2402) that can beimplemented in the pump systems 2300, 2400, 2500 of FIGS. 23-25 and/orany other thermal transport pump system.

FIG. 31A illustrates at least a portion of a first example staticseparator 3102 (e.g., a first example filter, the first separator 2302,the second separator 2402). The first static separator 3102 includesbaffles 3104 that define at least one flow path through the first staticseparator 3102. The baffles 3104 can be formed via sheet metals and/oradditive manufacturing. The baffles 3104 include an oil absorbentmaterial 3105, such as polyurethane, polypropylene, polyethylene,cross-linked polymers, talc, aluminum starch, rice starch, and/orsilica.

In the illustrated example of FIG. 31A, the baffles 3104 define a firstflow path 3106A and a second flow path 3106B through which the mixtureof the supercritical fluid 3012 and the oil 3010 can flow. Inparticular, the first flow path 3106A is defined between a first baffle3104A and a second baffle 3104B. Further, the second flow path 3106B isdefined between the second baffle 3104B and a third baffle 3104C. InFIG. 31A, the first flow path 3106A is adjacent to the second flow path3106B in a circumferential direction defined by the first staticseparator 3102. Additionally or alternatively, the first flow path 3106Acan be adjacent to the second flow path 3106B in a radial directiondefined by the first static separator 3102. When the oil 3010 contactsthe baffles 3104, the oil absorbent material 3105 of the baffles 3104causes the oil 3010 to stick to the baffles 3104 as the supercriticalfluid 3012 continues to flow between the baffles 3104.

In some examples, a weight of the oil 3010 eventually causes the oil3010 to fall from the baffles 3104. For example, as the oil 3010accumulate in the baffles 3104, the oil 3010 can fuse together, whichincreases the weight of the oil 3010 and, in turn, causes the oil 3010to fall from the baffles 3104. Specifically, the oil absorbent material3105 of the baffles 3104 can include an additive that mixes with oil tocause the oil 3010 to become more viscous. Additionally oralternatively, the rolling element bearings that utilize the oil mayinclude the additive that makes the oil 3010 more viscous. Thus, thebaffles 3104 can cause cohesion and adhesion properties associated withthe oil 3010 to be improved to increase a likelihood that the oildroplets 3010 bond together in response to contacting the baffles 3104.

Accordingly, one or more ducts in fluid connection with an oil supplyand/or the motor housing 2308 (e.g., the secondary duct 3004) can bepositioned below the baffles 3104 to enable the oil 3010 to bere-utilized. Furthermore, a position of the duct(s) can be based on ageometry of the baffles 3104 such that the oil 3010 that departs fromthe baffles 3104 falls directly into the duct(s). For example, gravitycan cause the oil 3010 to accumulate in the baffles 3104 at one or morepoints of lower elevation and, in turn, the oil 3010 can drip from thelower elevation point(s) into the duct(s). Additionally oralternatively, one or more distinct portions of the baffles 3104 mayinclude the oil absorbent material 3105 and, in turn, a position(s) ofthe duct(s) can be based on a location(s) of the portion(s) of thebaffles 3104 that include the oil absorbent material 3105 and, thus,collect the oil 3010.

In some examples, when the oil 3010 is to be collected and maintained inthe first static separator 3102 until the first static separator 3102encounters maintenance or replacement, the oil absorbent material of thebaffles 3104 does not include the additive that makes the oil 3010 moreviscous. In such examples, the baffles 3104 reduce a likelihood that theweight of the oil droplets 3010 increases and, in turn, minimizes orotherwise reduces a likelihood that the oil droplets 3010 fall from thebaffles 3104. Furthermore, to prevent the oil 3010 from escaping fromthe first static separator 3102, the first static separator 3102 caninclude an increased quantity of circumferential layers defined by thebaffles 3104. As such, outer circumferential layers defined by thebaffles 3104 can catch oil 3010 that manages to fall from respectiveinner circumferential layers of the baffles 3104. Additionally oralternatively, a collection container can be positioned at leastpartially around an outermost layer of the baffles 3104 (e.g., around abottom portion of the outermost layer) such that the collectioncontainer can catch the oil 3010 that passes through and fall from thebaffles 3104. Thus, the first static separator 3102 can prevent the oil3010 from escaping.

FIG. 31B illustrates another example implementation of the first staticseparator 3102. In FIG. 31B, the first static separator 3102 includesthe baffles 3104 oriented vertically instead of horizontally, as shownin FIG. 31A. The baffles 3104 form a flow path 3107 that prevents theoil 3010 from flowing through the first static separator 3102 withoutcontacting the oil absorbent material 3105. Accordingly, as the mixtureof the supercritical fluid 3012 and the oil 3010 flows between thebaffles 3104, the oil absorbent material 3105 absorbs the oil 3010.Furthermore, a weight of the oil 3010 and the vertical orientation ofthe baffles 3104 enables the absorbed oil 3010 to collect at a bottomportion 3110 of the baffles 3104. As such, a location where the oil 3010would fall from the baffles 3104 is limited by a size of the bottomportion 3110 of the baffles 3104. In turn, an oil collection duct (e.g.,the secondary duct 3004) can be positioned below the bottom portion 3110of the baffles 3104 to collect the oil 3010 that falls from the baffles3104. Accordingly, the collected oil 3010 can be rerouted to an oilstorage tank for storage and/or the motor housing 2308 for usage aslubrication, as discussed below in association with FIG. 35 .

FIG. 31C illustrates a second example static separator 3120 (e.g., asecond filter, the first separator 2302, the second separator 2402). Thesecond static separator 3120 includes baffles 3122 that form a primaryflow path 3124. Further, the second static separator 3120 includes anoil collection duct 3126 that forms a secondary flow path 3128 below thebaffles 3122. The secondary flow path 3128 can be in connection with anoil supply and/or can recirculate the oil 3010 back to the motor housing2308 such that the oil 3010 can return to the rolling element bearings2325, 2327, 2808, 2820 of FIGS. 23-26 and/or 28 for lubrication throughan oil duct, as discussed below in association with FIG. 35 .

In FIG. 31C, connector ducts 3130 connect the secondary flow path 3128to the primary flow path 3124. In some examples, the oil collection duct3126 is in direct connection with one or more lowermost elevation pointsof the baffles 3122. In such examples, the second static separator 3120does not require the connector ducts 3130 to couple the secondary flowpath 3128 to the primary flow path 3124.

In FIG. 31C, the mixture of the supercritical fluid 3012 and the oil3010 enters an inlet 3132 of the primary flow path 3124. A first portion3134 of the baffles 3122 causes the mixture to flow downward. Further, asecond portion 3136 of the baffles 3122 causes the mixture to transitionfrom the downward flow to a horizontal flow. The second portion 3136 ofthe baffles 3122 includes the lowermost point of the respective baffles3122, which the connector ducts 3130 extend from. In turn, gravity and ahigher density of the oil 3010 compared to the supercritical fluid 3012cause the oil 3010 to continue flowing downward through the secondportion 3136 of the baffles 3122 while the supercritical fluid 3012transitions to the horizontal flow. As a result, the oil 3010 flowsthrough the connector ducts 3130 and into the oil collection duct 3126,which enables the oil 3010 to be collected and/or reutilized. Moreover,a third portion 3138 of the baffles 3122 can cause the supercriticalfluid 3012 separated from the oil 3010 to flow upwards. Although theillustrated example of FIG. 31C utilizes four of the baffles 3122, anyquantity of the baffles 3122 can be utilized to separate thesupercritical fluid 3012 from the oil 3010 given operating parameters ofthe associated pump system 2300, 2400, 2500, 2600, 2800.

FIG. 32 is a schematic representation of a first example layout 3200that can be utilized for the pump systems 2300, 2400, 2500, 2600, 2800of FIGS. 23-26 and/or 28 . In FIG. 32 , supercritical fluid flowingthrough a pump inlet 3202 is driven by an impeller 3204 (e.g., alow-head impeller). A first portion of the supercritical fluid flowsthrough an outlet 3206 of a compressor housing 3207 and into a duct3209. In turn, an eductor 3211 helps pull the supercritical fluidthrough the duct 3209 towards a downstream thermal transport bus (e.g.,the thermal transport bus 202 of FIG. 3 ).

Furthermore, a second portion of the supercritical fluid flows past theimpeller 3204, around a shaft 3213 and into a motor housing 3208.Accordingly, the second portion of the supercritical fluid flows throughmixes with oil used to lubricate rolling element bearings utilized tosupport the shaft 3213. Furthermore, the second portion of thesupercritical fluid flows through a gas-gas seal 3210 before flow isstopped by a gas-oil seal 3212. In turn, a mixture of the supercriticalfluid and the oil collected by the supercritical fluid exits through anoutlet 3214 of the motor housing 3208 and is merged with the firstportion of the supercritical fluid in the duct 3209. An oil separator3216 (e.g., the first separator 2302 of FIG. 23 , the second separator2402 of FIGS. 24-26 and 28 , the third separator of FIG. 25 , the first,second, and third rotary separators 3002, 3020, 3040 of FIGS. 30A-C,and/or the first and second static separators 3102, 3120 of FIGS. 31A-C)positioned in the duct 3209 then separates the oil in the mixture fromthe supercritical fluid and enables the supercritical fluid to continuethrough the duct 3209 toward the thermal transport bus 202 whilewithholding the oil. In some examples, another duct can be positionedbelow the oil separator 3216 to transport oil collected by the oilseparator 3216 back to an oil supply and/or to the motor housing 3208where it can be used to lubricate the rolling element bearings, asdiscussed below in association with FIG. 35 .

FIG. 33 is a schematic representation of a second example layout 3300that can be utilized for the pump systems 2300, 2400, 2500, 2600, 2800of FIGS. 23-26 and/or 28 . In the second example layout 3300, the oilseparator 3216 is positioned in a return duct 3302 that is in fluidconnection with the motor housing 3208 and the compressor housing 3207at the pump inlet 3202. Accordingly, the mixture of the second portionof the supercritical fluid and the oil flows through the return duct3302 where the oil separator 3216 causes the oil to separate from thesupercritical fluid. Accordingly, the supercritical fluid can flow backinto the compressor housing 3207 and, in turn, be driven by the impeller3204. Moreover, a valve 3304 is positioned in the return duct 3302 toprevent the supercritical fluid that enters through the inlet 3202 fromflowing through the return duct 3302.

FIG. 34 is a schematic representation of a third example layout 3400 ofthe pump systems 2300, 2400, 2500, 2600, 2800 of FIGS. 23-26 and/or 28 .In the third example layout 3400, the return duct 3302 includes an oiltank 3402 upstream of the oil separator 3216. Accordingly, as the oil inthe mixture flows through the oil tank 3402, the oil in the mixture canbe attracted to oil stored in the oil tank 3402. Specifically, the oilin the mixture may be mixed with the aforementioned additive (e.g.,within the rolling element bearings 2325, 2327, 2808, 2820 of FIGS.23-26 and/or 28 that can be utilized to mount the shaft 3213) thatincreases the adhesion and cohesion properties of the oil. As a result,the increased adhesion and cohesion of the oil in the mixture can enablethe oil in the mixture to be pulled into the stored oil. Furthermore,the stored oil may be positioned below the return duct 3302 such thatgravity helps move the oil in the mixture into the oil tank 3402 whilethe second portion of the supercritical fluid continues to flow throughthe return duct 3302.

FIG. 35 is a schematic representation of a fourth example layout 3500 ofthe pump systems 2300, 2400, 2500, 2600, 2800 of FIGS. 23-26 and 28 . Inthe fourth example layout 3500, the oil that is separated from thesupercritical fluid by the oil separator 3216 enters an oil duct 3502(e.g., secondary flow path 3128 of FIG. 31C). In turn, the oil passesthrough an oil filter 3504 and into an oil supply 3506. Further, an oilpump 3508 can pump the fluid from the oil supply 3506 into the pump 3510where it can lubricate bearings (e.g., the rolling element bearings2325, 2327, 2808, 2820 of FIGS. 23-26 and/or 28 ). Moreover, an oilscavenge duct 3512 can carry a portion of the mixture from the pump 3510to the oil filter 3504. For example, the oil scavenge duct 3512 can befluidly coupled to the oil collection duct 3126 (FIG. 31C) to receivethe oil flowing through the secondary flow path 3128 (FIG. 31C).Additionally or alternatively, the oil scavenge duct 3512 can bepositioned to receive the oil 3010 (FIGS. 31A-C) that falls from thebaffles 3104, 3104A, 3104B, 3104C (FIGS. 31A-B) of the first examplestatic separator 3102. As a result, the oil can pass into the oil supply3506. Additionally, a release duct 3514 in connection with the oilsupply 3506 allows any supercritical fluid that enters the oil supply3506 to be released into the atmosphere. Specifically, the release duct3514 includes a release valve 3516 that allows fluids to be released inresponse to encountering a pressure greater than a pressure threshold.

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for compressing fluid. For example, the means for compressingfluid may be implemented by the impeller 406 of FIG. 4 , the impeller2340 of FIGS. 23-26 and/or 28 , the impeller 3204 of FIG. 32-33 , and/orany other impellers described herein.

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for housing the means for compressing. For example, the means forhousing may be implemented by the compressor collector 408 of FIG. 4 ,the pump housing 2306 of FIGS. 23-26 and/or 28 , the motor housing 2308of FIGS. 23-4 and/or 28 , the compressor housing 3207 of FIGS. 32-33 ,and/or the motor housing 3208 of FIGS. 32-33 .

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for transporting fluid. For example, the means for transportingthe fluid may be implemented by the thermal transport bus 202 of FIG. 2, the fluid conduits 402 of FIG. 4 , the duct 2304 of FIGS. 23-26, and28 , the duct 3003 of FIGS. 30A-C, the duct 3209 of FIG. 32 , the duct3302 of FIGS. 33-34 , and/or any other pump output duct disclosedherein.

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for separating supercritical fluid and oil. For example, the meansfor separating may be implemented by the first separator 2302 of FIG. 23, the second separator 2402 of FIGS. 24-26 and 28 , the third separator2506 of FIG. 25 , the first, second, and/or third rotary separators3002, 3020, 3040 of FIGS. 30A-C, and/or the first and/or second staticseparators 3102, 3120 of FIGS. 31A-C.

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for rotating the means for compressing. For example, the means forrotating may be implemented by the motor 2320 of FIGS. 23-26 and/or 28and/or the shaft 2324 of FIGS. 23-26 and/or 28 .

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includemeans for increasing an angular velocity of the means for compressingrelative to the means for rotating. For example, the means forincreasing the angular velocity of the means for compressing may beimplemented by the gearbox 2609 of FIGS. 26-27 .

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includefirst means for radially supporting the means for rotating. The firstmeans for radially supporting can include a first stiffness. Forexample, the first means for radially supporting may be implemented bythe first bearing assembly 2802 of FIGS. 28 and/or 29 .

In some examples, the pump systems 2300, 2400, 2500, 2600, 2800 includesecond means for radially supporting the means for rotating. The secondmeans for radially supporting can include a second stiffness differentfrom (e.g., less than) the first stiffness. For example, the secondmeans for supporting may be implemented by the second bearing assembly2804 of FIGS. 28 and/or 29 .

Example oil lubricated pump architectures with one or more oilseparators are disclosed herein. The example pump systems disclosedherein include oil separators to enable fluid (e.g., heat exchange fluidsuch as supercritical fluid (e.g., sCO₂, etc.)) to mix with oil andsubsequently be separated from the oil. The oil separators enable thefluid to mix with oil while reducing safety risks associated with thethermal energy transfer that the fluid encounters. Accordingly, the oilseparators enable an impeller to be directly driven by a motor without ashroud separating the fluid from the motor. Moreover, the oil separatorsenable a quantity and/or complexity of components in the pump system tobe reduced.

Axial Flux Motor Driven Pump Systems for Pressurizing Fluid in ClosedLoop Systems

The operations of some example fluid pump systems and centrifugal fluidpump systems have an electric motor (e.g., motor 410) connected axiallyto an impeller (e.g., impeller 406) via an impeller shaft (e.g.,impeller shaft 466) as described in reference to FIG. 4 above. Theexample motor 410 illustrated in FIG. 4 includes a stator to generate atorque on a rotor via magnetic forces. The example stator includescopper wire windings, referred to as electromagnetic coils, that arewrapped around iron magnetic cores, poles, and/or rods that are orientedperpendicular to the axis of rotation of the rotor. The electromagneticcoils are tightly wound around the poles such that they are runningparallel to the axis of rotation of the rotor. According to Faraday'slaw of induction, when an electric current is running through theelectromagnetic coils, a magnetic field is generated that flows aroundthe electromagnetic coil perpendicular to the direction of the electriccurrent flow. Therefore, if the electromagnetic coil is wound parallelto the axis of rotation of the motor, then the magnetic field that theelectromagnetic coil generates flows perpendicular to the axis ofrotation of the motor. Since the stator of the example motor 410produces a magnetic field that runs perpendicular, or radial, to theaxis of rotation of the motor 410, the example electric motor 410 thatdrives the rotor shaft 438 can be referred to as a radial flux motor.

In contrast to radial flux motors (e.g., electric motor 410), axial fluxmotors include electromagnetic coils and/or windings that are orientedperpendicular to the axis of rotation of the motor and/or the rotor. Theorientation of the electromagnetic coil windings causes theelectromagnetic coils to produce magnetic fields that flow parallel tothe axis of rotation of the motor and/or the rotor. Since the directionof magnetic flux is parallel to the axis of rotation, the stator and therotor in axial flux motors are designed as disks, plates, etc. thatincrease the distance the permanent magnets in the rotor are from theaxis of rotation but also decrease the axial length of the axial fluxmotor. The stator and the rotor of radial flux motors useelectromagnetic coils and permanent magnets that are axially longer thanthe electromagnetic coils and the permanent magnets in the axial fluxmotor because the radial flux motor relies on stronger magnetic forcesto produce a same torque as the axial flux motor. Since the axial fluxmotor is able to apply magnetic forces to the rotor at greater distancesfrom the axis of rotation that the radial flux motor, and since torqueis a product of force and distance, the axial flux motor can produce thesame torque on the rotor as the radial flux motor because theelectromagnetic coils and the permanent magnets are further away fromthe axis of rotation. This means that the axial flux motor can beaxially shorter but radially larger than the radial flux motor whilestill generating the same overall torque.

In examples disclosed herein, axial flux motors are used to drive pumpsystems that pressurize fluid in a closed loop system. In some examples,the fluid is a supercritical fluid. In some examples, the supercriticalfluid is supercritical carbon dioxide (sCO2). In some examples, theclosed loop system is a thermal management system (e.g., thermalmanagement system 200 of FIG. 3 ) that uses the sCO2 to transfer thermalenergy between heat exchangers (e.g., heat source heat exchanger 206and/or heat sink heat exchanger 208 of FIG. 3 ). In examples disclosedherein, axial flux motor driven pump systems for pressurizing fluid inclosed loop systems move a center of gravity (CG) of the pump systemcloser to a mounting flange used to mount the pump system to a mountingsurface (e.g., a wall, a beam, a support structure, etc.) relative toradial flux motor driven pump systems (e.g., thermal transport bus pump400). In examples disclosed herein, since the CG of the example axialflux motor driven pump system is closer to the mounting flange than theradial flux motor driven pump system, there is a smaller moment ortorque acting on the pump system and the mounting flange due to gravity,which reduces vibration and damage over time for the axial flux motordrive pump systems relative to the radial flux motor driven pumpsystems. In examples disclosed herein, the axial flux motor pump systemsaves space in the axial direction within an example aircraft on whichthe example axial flux motor driven pump system may be used. In examplesdisclosed herein, the surface (e.g., wall, structure, beam, etc.) onwhich the axial flux motor driven pump system is mounted may be thinnerthan a surface on which the radial flux motor driven pump system ismounted due to the reduction in CG overhang. In examples disclosedherein, the axial flux motor driven pump system includes a pump housing,an impeller, impeller shaft, etc. as a separate line replaceable unit tooptimize removal and/or maintenance of the pump, the motor, and/or othercomponents of the axial flux motor driven pump system relative to theradial flux motor driven pump system.

For the figures disclosed herein, identical numerals indicate the sameelements throughout the figures. FIG. 36 illustrates a cross-sectionalview of an axial flux motor driven pump system 3600 (“pump system 3600”)for pressurizing fluid (e.g., supercritical fluid (sCO2)) in a closedloop system (e.g., thermal management system 200 of FIG. 3 ). In someexamples, the pump system 3600 is used to pump sCO2 through a thermalmanagement system on an aircraft (e.g., aircraft 10 of FIG. 1 ) and/or agas turbine engine (e.g., gas turbine engine 100 of FIG. 2 ). As shownin FIG. 36 , the pump system 3600 includes an impeller 3602, an impellershaft 3604, radial impeller bearings 3606, a pump housing 3608, housingbolts 3609, a magnetic coupling 3610, an inner hub 3612, an outer hub3614, a barrier can 3616, barrier can bolts 3617, a coupling shaft 3618,a rotor shaft 3620, a splined interface 3622, a stator 3624, rotors3626, radial motor bearings 3628, a motor housing 3630, and a mountingflange 3632. Some of the architecture included in the example pumpsystem 3600 can be used in other pump systems described above, such aspump system 900 of FIG. 9 , pump system 2300-2600, 2800 of FIGS. 23-26,28 .

The example pump system 3600 illustrated in FIG. 36 includes theimpeller 3602 to pressurize the example fluid (e.g., sCO2) in theexample closed loop system (e.g., the thermal management system 200 ofFIG. 3 ). The example impeller 3602 is a component of the pump system3600 that is connected to the impeller shaft 3604 and rotates at a samerotational speed as the impeller shaft 3604. In some examples, theimpeller 3602 is same as or similar to impellers used in centrifugalpumps and includes vanes and/or blades to deflect flow of the incomingfluid radially outward into outlet flowlines. The example impeller 3602converts mechanical power of the motor (e.g., the stator 3624 and therotors 3626) into hydrodynamic power of the flowing fluid.

The example pump system 3600 illustrated in FIG. 36 includes theimpeller shaft 3604 to transfer torque from the motor (e.g., the stator3624, the rotors 3626, and the rotor shaft 3620) to the impeller 3602.In some examples, the impeller shaft 3604 is a hollow shaft to conservemass and includes a central rod along the axis of rotation of theimpeller shaft 3604 to maintain axial alignment of the impeller shaft3604. In some examples, the impeller shaft 3604 is manufactured withmetallic materials (e.g., titanium, aluminum alloys, etc.) and/orcomposite materials (e.g., carbon fiber, Kevlar®, etc.) via additivemanufacturing and/or subtractive manufacturing. The example impellershaft 3604 is constructed as multiple parts included in an assembly,however, in some examples, the impeller shaft 3604 is fabricated as asingle part and/or a preassembled structure.

The example pump system 3600 illustrated in FIG. 36 includes radialimpeller bearings 3606 to support radial loads (e.g., weight, forcedoscillations, etc.) of the impeller shaft 3604. The example radialimpeller bearings 3606 illustrated in FIG. 36 are rolling-elementbearings that include an inner race, an outer race, and rolling elements(e.g., balls, cylinders, etc.). The example radial impeller bearings3606 can support the radial loads and thrust loads of the impeller shaft3604 since the radial impeller bearings 3606 illustrated in FIG. 36 arerolling element bearings. For example, the impeller shaft 3604 may beattached to the inner races of the radial impeller bearings 3606 suchthat the impeller shaft 3604 could not move significantly far (e.g.,less than one millimeter (mm)) in the axial direction. The exampleradial impeller bearings 3606 include dry lubricants (e.g., silvercoating, graphite, molybdenum disulfide, etc.) to reduce frictionalforces between the inner ring, the outer ring, and the rolling elementswithout a risk of contaminating the fluid that the pump system 3600pressurizes. In some examples, the radial impeller bearings 3606 includeliquid lubricants (e.g., oil-based lubricants, water-based lubricants,silicone-based lubricants, etc.) to reduce frictional forces between theinner ring, the outer ring, and the rolling elements, and the pumpsystem 3600 includes an oil separator (e.g., oil separator 3216 of FIGS.32-35 ) to remove liquid lubricants of the radial impeller bearings 3606from the fluid (e.g., the sCO2).

In some examples, the radial impeller bearings 3606 are foil bearingsthat support the radial loads of the impeller shaft 3604. For examplesin which the radial impeller bearings 3606 are foil bearings, the radialimpeller bearings 3606 include a journal lining and a spring-loadedfoil. For examples in which the radial impeller bearings 3606 are foilbearings, the spring-loaded foil supports the radial loads of theimpeller shaft 3604 during start-up and stopping of the pump system3600. For examples in which the radial impeller bearings 3606 are foilbearings, as the angular velocity of the impeller shaft 3604 increases,a working fluid (e.g., air, nitrogen, argon, etc.) gets pulled into thejournal lining due to viscosity effects of the working fluid and aworking fluid pressure within the example radial impeller bearings 3606increases. For examples in which the radial impeller bearings 3606 arefoil bearings, once the working fluid pressure within the journal liningincreases to a certain threshold (e.g., 100 force-pounds per square inch(psi)), the spring-load foil gets pushed outward, and the working fluidpressure fully supports the radial loads of the impeller shaft 3604. Forexamples in which the radial impeller bearings 3606 are foil bearings,the radial impeller bearings 3606 do not support axial loads of theimpeller shaft 3604, and no liquid lubricants are used. Therefore, ifthe example radial impeller bearings 3606 are foil bearings, the exampleimpeller shaft 3604 includes one or more shafts and/or one or more disksattached to the impeller shaft 3604, oriented perpendicular to the axisof rotation, and protruding radially outward from the impeller shaft3604, similar to thrust shafts 532, 632, 742 of FIGS. 5, 6 , and/or 7.In some examples, if the radial impeller bearings 3606 are foilbearings, the example pump system 3600 includes thrust bearings (e.g.,thrust bearings 534, 634, 744 of FIGS. 5, 6 , and/or 7) to support axialloads of the impeller shaft via interfacing with the example thrustshafts.

The example pump system 3600 illustrated in FIG. 36 includes the pumphousing 3608 to support the radial impeller bearings 3606. The examplepump housing 3608 prevents the radial impeller bearings 3606 from movingsignificantly far (e.g., less than 0.1 mm) in the radial direction oraxial direction. In the illustrated example of FIG. 36 , the pumphousing 3608 includes three separate parts assembled together viafasteners (e.g., bolts, screws, adhesives, etc.). In some examples, theparts of the pump housing 3608 are fabricated separately via additivemanufacturing and/or subtractive manufacturing prior to assembly. Insome examples, the pump housing 3608 is a single part fabricated viaadditive manufacturing and/or subtractive manufacturing. The examplepump housing 3608 is fastened to the example motor housing 3630 viahousing bolts 3609. Although two housing bolts 3609 are illustrated inFIG. 36 , two or more housing bolts 3609 may be included in the pumpsystem 3600.

The example pump system 3600 illustrated in FIG. 36 includes themagnetic coupling 3610 to connect the impeller shaft 3604 to thecoupling shaft 3618. The example magnetic coupling 3610 of FIG. 36 isthe same as and/or is similar to example magnetic couplings 526, 626,720 illustrated in FIGS. 5, 6 , and/or 7 and transfers torque from thecoupling shaft 3618 to the impeller shaft 3604 via magnetic forces. Insome examples, the inner hub 3612 of the magnetic coupling 3610 includesa first set of permanent magnets, and the outer hub 3614 of the magneticcoupling 3610 includes a second set of permanent magnets. The examplefirst set of permanent magnets and the example second set of permanentmagnets alternate in polarity about the axis of rotation of the impellershaft 3604 and/or the coupling shaft 3618, and the attractive magneticforces between the first set of magnets and the second set of magnetscause the outer hub 3614 to drive the rotation of the inner hub 3612.

The example pump system 3600 illustrated in FIG. 36 includes the barriercan 3616 to help prevent fluid from contacting the rotors 3626, thestator 3624, and/or other parts and/or components that affect theoperability of the motor. The example barrier can 3616 illustrated inFIG. 36 includes metallic and/or non-metallic materials and may be thesame as and/or similar to the example barrier cans 536, 636, 728 ofFIGS. 5-7, 1500 of FIGS. 15 , and/or 1900 of FIG. 19 . The examplebarrier can 3616 fastens to the pump housing 3608 via barrier can bolts3617. In some examples, the barrier can 3616 connects to the pumphousing 3608 via the barrier can bolts 3617 and/or other fasteners, suchas screws, dowels, rods, pins, adhesives, magnetic forces, interferencefits, etc.

The example pump system 3600 illustrated in FIG. 36 includes thecoupling shaft 3618 to house the outer hub 3614 of the magnetic coupling3610 and to transfer torque from the rotor shaft 3620 to the impellershaft 3604 via the magnetic coupling 3610. In some examples, thecoupling shaft 3618 includes the outer hub 3614 and/or the second set ofpermanent magnets. The example coupling shaft 3618 of FIG. 36 interactswith the rotor shaft 3620 via the splined interface 3622. In someexamples, the coupling shaft 3618 and the rotor shaft 3620 includesplines (e.g., teeth, ridges, v-cuts, etc.) that physically interlock tocreate the splined interface 3622. The splined interface 3622 is aphysical connection at which the rotor shaft 3620 splines apply a forceto the coupling shaft 3618 splines and, in turn, transfer a torque fromthe rotor shaft 3620 to the coupling shaft 3618. The example splinedinterface 3622 causes the coupling shaft 3618 to rotate at a same rateas the rotor shaft 3620.

The example pump system 3600 illustrated in FIG. 36 includes the stator3624, the rotors 3626, and the radial motor bearings 3628 to providemechanical power to the pump system 3600. The stator 3624, the rotors3626, and the radial motor bearings 3628 of the example pump system 3600are included in an axial flux motor of the system, which operates inaccordance with the previous description above. In some examples, thestator 3624 includes electromagnetic coils that are wrapped around coresof ferrous material (e.g., soft iron, nickel, cobalt, etc.) such thatthe electromagnetic coils run perpendicular to the axis of rotation andgenerate a magnetic flux parallel to the axis of rotation. The examplestator 3624 supports and/or houses the example radial motor bearings3628 such that the radial motor bearings 3628 do not move significantlyfar (e.g., less than 0.005 inches) from the intended position of theradial motor bearings 3628 in the pump system 3600 due to radial forcesand/or axial forces that the rotors 3626 and/or the rotor shaft 3620generate. The example rotors 3626 include a first rotor disk positionedon a front side of the stator 3624 and a second rotor disk positioned ona back side of the stator 3624. The example first rotor disk and theexample second rotor disk include permanent magnets, and the magneticflux(es) that the example stator 3624 generates attract and/or repel thepermanent magnets. The example stator 3624 generates heat due toelectrical resistances in the electromagnetic coils. In some examples,cooling channels, linings, pipes, jackets, etc. with flowing liquidcoolants (e.g., water, oil, deionized water, inhibited glycol,dielectric fluids, heat exchange fluids such as supercritical fluids(e.g., sCO2, etc.)) are included in and/or surrounding the stator 3624to transfer heat to the liquid coolants. In some examples, cooling finsand/or vents are fixed to the stator 3624 to transfer heat to ambientair.

The example rotors 3626 of the pump system 3600 are attached to theexample rotor shaft 3620 via fasteners (e.g., bolts, pins, dowels,adhesives, magnetic forces, interference fits, etc.). In some examples,the rotors 3626 are also attached to an inner race and/or an outer raceof the radial motor bearings 3628. The example pump system 3600illustrated in FIG. 36 includes the example radial motor bearings 3628to support radial loads (e.g., weight, forced oscillation, etc.) thatthe rotor shaft 3620 generates. The example radial motor bearings 3628of FIG. 36 also support radial loads of the rotors 3626 via themechanical connection(s) (e.g., fasteners, adhesives, magnetic forces,interference fits, etc.) between the rotors 3626 and the rotor shaft3620. The example radial motor bearings 3628 are rolling-elementbearings that use liquid lubricants (e.g., oil-based lubricants,water-based lubricants, silicone-based lubricants, etc.) to reducefriction between the inner race, the outer race, and/or rolling elementsof the radial motor bearings 3628. The example rotors 3626 and/or theexample rotor shaft 3620 produce radial loads and axial loads that theradial motor bearings 3628 support. Additionally or alternatively,thrust bearings may be used in the axial flux motor to support the axialloads that the rotors 3626 and/or the rotor shaft 3620 produce.Additionally or alternatively, the axial flux motor may include thrustbearings to support the axial loads that the rotors 3626 and/or therotor shaft 3620 produce.

The example pump system 3600 illustrated in FIG. 36 includes the motorhousing 3630 to support the stator 3624 and/or the pump housing 3608 ofthe pump system 3600. In some examples, the motor housing 3630 is oneadditively manufactured and/or subtractive manufactured part toaccommodate the stator 3624, the rotors 3626, the radial motor bearings3628, the rotor shaft 3620, the coupling shaft 3618, the barrier can3616, the outer hub 3614, the inner hub 3612, the magnetic coupling3610, a portion of the mounting flange 3632, and/or a portion of thepump housing 3608. In the illustrated example of FIG. 36 , the motorhousing 3630 includes different parts manufactured separately (e.g., viaadditive manufacturing and/or subtractive manufacturing) and assembledtogether (e.g., via bolts, adhesives, dowels, pins, and/or interferencefits) to accommodate the stator 3624, the rotors 3626, the radial motorbearings 3628, the rotor shaft 3620, the coupling shaft 3618, thebarrier can 3616, the outer hub 3614, the inner hub 3612, the magneticcoupling 3610, a portion of the mounting flange 3632, and/or a portionof the pump housing 3608 without interfering with the stator 3624, therotors 3626, the radial motor bearing 3628, the motor housing 3630,and/or the mounting flange 3632.

The example pump system 3600 illustrated in FIG. 36 includes themounting flange 3632 to mount the example pump system 3600 to a surface(e.g., wall, assembled bars, beam(s), etc.). The example mounting flange3632 includes holes through which fasteners (e.g., bolts, pins, clamps,etc.) can fit and attach the mounting flange 3632 to the mountingsurface. The mounting flange 3632 of FIG. 36 is made of materials (e.g.,aluminum, steel, titanium, etc.) that are strong enough to withstandbending and/or shearing stresses the pump system 3600 may impose on themounting flange 3632 during operation and/or non-operation. The motorhousing 3630 is connected to the mounting flange 3632 via one or morefasteners (e.g., bolts, adhesives, interference fits, etc.), and may befastened to the mounting flange 3632 before the example mounting flange3632 is mounted to the mounting surface. In some examples, the motorhousing 3630 and the mounting flange 3632 are the same part via additivemanufacturing and/or subtractive manufacturing. In some examples, themounting flange 3632 is not included in the pump system 3600, and themotor housing 3630 directly contacts the mounting surface. Additionallyor alternatively, the example motor housing 3630 includes holes (e.g.,threaded holes, clearance holes, etc.) in which one or more fasteners(e.g., bolts, dowels, interference fits, etc.) can fit to attach thepump system 3600 to the mounting surface.

FIG. 37 illustrates a cross-sectional view of an axial flux motor drivenpump system 3700 (“pump system 3700”) for pressurizing fluid (e.g.,supercritical fluid (sCO2)) in a closed loop system (e.g., thermalmanagement system 200 of FIG. 3 ). In some examples, the pump system3700 is used to pump sCO2 through a thermal management system on anaircraft (e.g., aircraft 10 of FIG. 1 ) and/or a gas turbine engine(e.g., gas turbine engine 100 of FIG. 2 ). As shown in FIG. 37 , thepump system 3700 includes an impeller 3702, an impeller shaft 3704,radial impeller bearings 3706, a pump housing 3708, housing bolts 3709,a piston seal 3710, a rotor shaft 3720, a splined interface 3722, astator 3724, rotors 3726, radial motor bearings 3728, a motor housing3730, and a mounting flange 3732.

The example pump system 3700 illustrated in FIG. 37 includes theimpeller 3702 to pressurize the example fluid (e.g., sCO2) in theexample closed loop system (e.g., the thermal management system 200 ofFIG. 3 ). The example impeller 3702 is a component of the pump system3700 that is connected to the impeller shaft 3704 and rotates at a samerotational speed as the impeller shaft 3704. In some examples, theimpeller 3702 is same as or similar to impellers used in centrifugalpumps and includes vanes and/or blades to deflect flow of the incomingfluid radially outward into outlet flowlines. The example impeller 3702converts mechanical power of the motor (e.g., the stator 3724 and therotors 3726) into hydrodynamic power of the flowing fluid.

The example pump system 3700 illustrated in FIG. 37 includes theimpeller shaft 3704 to transfer torque from the motor (e.g., the stator3724, the rotors 3726, and the rotor shaft 3720) to the impeller 3702.In some examples, the impeller shaft 3704 is a hollow shaft to conservemass and includes a central rod along the axis of rotation of theimpeller shaft 3704 to maintain axial alignment of the impeller shaft3704. In some examples, the impeller shaft 3704 is manufactured withmetallic materials (e.g., titanium, aluminum alloys, etc.) and/orcomposite materials (e.g., carbon fiber, Kevlar®, etc.) via additivemanufacturing and/or subtractive manufacturing. The example impellershaft 3704 is constructed as multiple parts included in an assembly,however, in some examples, the impeller shaft 3704 is fabricated as asingle part and/or a preassembled structure.

The example pump system 3700 illustrated in FIG. 37 includes radialimpeller bearings 3706 to support radial loads (e.g., weight, forcedoscillations, etc.) of the impeller shaft 3704. The example radialimpeller bearings 3706 illustrated in FIG. 37 are rolling-elementbearings that include an inner race, an outer race, and rolling elements(e.g., balls, cylinders, etc.). The example radial impeller bearings3706 can support the radial loads and thrust loads of the impeller shaft3704 since the radial impeller bearings 3706 illustrated in FIG. 37 arerolling element bearings. For example, the impeller shaft 3704 may beattached to the inner races of the radial impeller bearings 3706 suchthat the impeller shaft 3704 could not move significantly far (e.g.,less than 0.005 inches) in the axial direction. The example radialimpeller bearings 3706 include dry lubricants (e.g., silver coating,graphite, molybdenum disulfide, etc.) to reduce frictional forcesbetween the inner ring, the outer ring, and the rolling elements withouta risk of contaminating the fluid that the pump system 3700 pressurizes.In some examples, the radial impeller bearings 3706 include liquidlubricants (e.g., oil-based lubricants, water-based lubricants,silicone-based lubricants, etc.) to reduce frictional forces between theinner ring, the outer ring, and the rolling elements, and the pumpsystem 3700 includes an oil separator (e.g., oil separator 3216 of FIGS.32-35 ) to remove liquid lubricants of the radial impeller bearings 3706from the fluid (e.g., the sCO2).

In some examples, the radial impeller bearings 3706 are foil bearingsthat support the radial loads of the impeller shaft 3704. For examplesin which the radial impeller bearings 3706 are foil bearings, the radialimpeller bearings 3706 include a journal lining and a spring-loadedfoil. For examples in which the radial impeller bearings 3706 are foilbearings, the spring-loaded foil supports the radial loads of theimpeller shaft 3704 during start-up and stopping of the pump system3700. For examples in which the radial impeller bearings 3706 are foilbearings, as the angular velocity of the impeller shaft 3704 increases,a working fluid (e.g., air, nitrogen, argon, etc.) gets pulled into thejournal lining due to viscosity effects of the working fluid and aworking fluid pressure within the example radial impeller bearings 3706increases. For examples in which the radial impeller bearings 3706 arefoil bearings, once the working fluid pressure within the journal liningincreases to a certain threshold (e.g., 100 force-pounds per square inch(psi)), the spring-load foil gets pushed outward, and the working fluidpressure fully supports the radial loads of the impeller shaft 3704. Forexamples in which the radial impeller bearings 3706 are foil bearings,the radial impeller bearings 3706 do not support axial loads of theimpeller shaft 3704, and no liquid lubricants are used. Therefore, ifthe example radial impeller bearings 3706 are foil bearings, the exampleimpeller shaft 3704 includes one or more shafts and/or one or more disksattached to the impeller shaft 3704, oriented perpendicular to the axisof rotation, and protruding radially outward from the impeller shaft3704, similar to thrust shafts 532, 632, 742 of FIGS. 5, 6 , and/or 7.In some examples, if the radial impeller bearings 3706 are foilbearings, the example pump system 3700 includes thrust bearings (e.g.,thrust bearings 534, 634, 744 of FIGS. 5, 6 , and/or 7) to support axialloads of the impeller shaft via interfacing with the example thrustshafts.

The example pump system 3700 illustrated in FIG. 37 includes the pumphousing 3708 to support the radial impeller bearings 3706. The examplepump housing 3708 prevents the radial impeller bearings 3706 from movingsignificantly far (e.g., less than 0.005 inches) in the radial directionor axial direction. In the illustrated example of FIG. 37 , the pumphousing 3708 includes three separate parts assembled together viafasteners (e.g., bolts, screws, adhesives, etc.). In some examples, theparts of the pump housing 3708 are fabricated separately via additivemanufacturing and/or subtractive manufacturing prior to assembly. Insome examples, the pump housing 3708 is a single part fabricated viaadditive manufacturing and/or subtractive manufacturing. The examplepump housing 3708 is fastened to the example motor housing 3730 viahousing bolts 3709. Although two housing bolts 3709 are illustrated inFIG. 37 , two or more housing bolts 3709 may be included in the pumpsystem 3700.

The example pump system 3700 illustrated in FIG. 37 includes the pistonseal 3710 to seal the fluid from the axial flux motor including thestator 3724, the rotors 3726, the radial motor bearings 3728, the motorhousing 3730, and/or the mounting flange 3732. In some examples, thepiston seal 3710 prevents fluid from entering the axial flux motorand/or the motor housing 3730, and in some examples, the piston seal3710 permits a significantly small amount of fluid (e.g., less than 0.01fluid ounces) into the motor housing 3730 while the example pump system3700 operates. In some examples, the piston seal 3710 of example pumpsystem 3700 is a single-acting piston seal that contains pressure on oneside of the seal and blocks fluid from flowing from the high pressureside to the low pressure side. The example piston seal 3710 is locatedin and/or attached to a notch cut into the inner surface of the rotorshaft 3720. In some examples, the fluid is sCO2 pressurized to at least1000 pounds per square inch (psi), and the piston seal 3710 is includedin the rotor shaft 3720 to withstand the pressure differential betweenthe fluid and the air pressure within the axial flux motor and toprevent and/or inhibit the fluid from contacting the stator 3724 and/orthe rotors 3726.

The example pump system 3700 illustrated in FIG. 37 includes the rotorshaft 3720 to transfer torque from the axial flux motor (e.g., therotors 3726) to the impeller shaft 3704 via the splined interface 3722.In some examples, the impeller shaft 3704 and the rotor shaft 3720include splines (e.g., teeth, keys, ridges, v-cuts, etc.) and/orserrations that physically interlock creating the splined interface3722. The splined interface 3722 is a physical connection at which therotor shaft 3720 splines apply a force to the impeller shaft 3704splines and, in turn, transfer a torque from the rotor shaft 3720 to theimpeller shaft 3704. The example splined interface 3722 causes theimpeller shaft 3704 to rotate at a same rate as the rotor shaft 3720.

The example pump system 3700 illustrated in FIG. 37 includes the stator3724, the rotors 3726, and the radial motor bearings 3728 to providemechanical power to the pump system 3700. The stator 3724, the rotors3726, and the radial motor bearings 3728 of the example pump system 3700are included in an axial flux motor of the system, which operates inaccordance with the previous description above. In some examples, thestator 3724 includes electromagnetic coils that are wrapped around coresof ferrous material (e.g., soft iron, nickel, cobalt, etc.) such thatthe electromagnetic coils are aligned perpendicular to the axis ofrotation and generate a magnetic flux parallel to the axis of rotation.The example stator 3724 supports and/or houses the example radial motorbearings 3728 such that the radial motor bearings 3728 do not movesignificantly far (e.g., less than 0.005 inches) from the intendedposition of the radial motor bearings 3728 in the pump system 3700 dueto radial forces and/or axial forces that the rotors 3726 and/or therotor shaft 3720 generate. The example rotors 3726 include a first rotordisk positioned on a front side of the stator 3724 and a second rotordisk positioned on a back side of the stator 3724. The example firstrotor disk and the example second rotor disk include permanent magnets,and the magnetic flux(es) that the example stator 3724 generates attractand/or repel the permanent magnets. The example stator 3724 generatesheat due to electrical resistances in the electromagnetic coils. In someexamples, cooling channels, linings, pipes, jackets, etc. with flowingliquid coolants (e.g., water, oil, deionized water, inhibited glycol,dielectric fluids, heat exchange fluids such as supercritical fluids(e.g., sCO2, etc.)) are included in and/or surrounding the stator 3724to transfer heat to the liquid coolants. In some examples, cooling finsand/or vents are fixed to the stator 3724 to transfer heat to ambientair.

The example rotors 3726 of the pump system 3700 are attached to theexample rotor shaft 3720 via fasteners (e.g., bolts, pins, dowels,adhesives, magnetic forces, interference fits, etc.). In some examples,the rotors 3726 are also attached to inner race(s) and/or an outerrace(s) of the radial motor bearings 3728. The example pump system 3700illustrated in FIG. 37 includes the example radial motor bearings 3728to support radial loads (e.g., weight, forced oscillation, etc.) thatthe rotor shaft 3720 generates. The example radial motor bearings 3728of FIG. 37 also support radial loads of the rotors 3726 via themechanical connection(s) (e.g., fasteners, adhesives, magnetic forces,interference fits, etc.) between the rotors 3726 and the rotor shaft3720. The example radial motor bearings 3728 are rolling-elementbearings that use liquid lubricants (e.g., oil-based lubricants,water-based lubricants, silicone-based lubricants, etc.) to reducefriction between the inner race, the outer race, and/or rolling elementsof the radial motor bearings 3728. The example rotors 3726 and/or theexample rotor shaft 3720 produce radial loads and axial loads that theradial motor bearings 3728 support. Additionally or alternatively, theaxial flux motor may include thrust bearings to support the axial loadsthat the rotors 3726 and/or the rotor shaft 3720 produce.

The example pump system 3700 illustrated in FIG. 37 includes the motorhousing 3730 to support the stator 3724 and/or the pump housing 3708 ofthe pump system 3700. In some examples, the motor housing 3730 is oneadditively manufactured and/or subtractive manufactured part toaccommodate the stator 3724, the rotors 3726, the radial motor bearings3728, the rotor shaft 3720, the piston seal 3710, a portion of theimpeller shaft 3704, a portion of the mounting flange 3732, and/or aportion of the pump housing 3708. In the illustrated example of FIG. 37, the motor housing 3730 includes different parts manufacturedseparately (e.g., via additive manufacturing and/or subtractivemanufacturing) and assembled together (e.g., via bolts, adhesives,dowels, pins, and/or interference fits) to accommodate the stator 3724,the rotors 3726, the radial motor bearings 3728, the rotor shaft 3720,the piston seal 3710, a portion of the impeller shaft 3704, a portion ofthe mounting flange 3732, and/or a portion of the pump housing 3708without interfering with the stator 3724, the rotors 3726, the radialmotor bearing 3728, the motor housing 3730, and/or the mounting flange3732 in a way that would detract from a best mode use case of theexample pump system 3700.

The example pump system 3700 illustrated in FIG. 37 includes themounting flange 3732 to mount the example pump system 3700 to a surface(e.g., wall, assembled bars, beam(s), etc.). The example mounting flange3732 includes holes through which fasteners (e.g., bolts, pins, clamps,etc.) can fit and attach the mounting flange 3732 to the mountingsurface. The mounting flange 3732 of FIG. 37 is made of materials (e.g.,aluminum, steel, titanium, etc.) that are strong enough to withstandbending and/or shearing stresses the pump system 3700 may impose on themounting flange 3732 during operation and/or non-operation. The motorhousing 3730 is connected to the mounting flange 3732 via one or morefasteners (e.g., bolts, adhesives, interference fits, etc.), and may befastened to the mounting flange 3732 before the example mounting flange3732 is mounted to the mounting surface. In some examples the motorhousing 3730 and the mounting flange 3732 are the same part via additivemanufacturing and/or subtractive manufacturing. In some examples, themounting flange 3732 is not included in the pump system 3700, and themotor housing 3730 directly contacts the mounting surface. Additionallyor alternatively, the example motor housing 3730 includes holes in whichone or more fasteners (e.g., bolts, dowels, interference fits, etc.) canfit to attach the pump system 3700 to the mounting surface.

In some examples, the pump systems 3600, 3700 include means forincreasing kinetic energy of a fluid. For example, the means forincreasing may be implemented by the impellers 3602, 3702 and/or theimpeller shafts 3604, 3704 of FIGS. 36 and/or 37 . In some examples, themeans for increasing may include an electric motor, an impeller shaft,and/or an impeller.

In some examples, the pump systems 3600, 3700 include means forproviding torque. For example, the means for providing torque may beimplemented by the stators 3624, 3724, the rotors 3626, 3726, and/or thecoupling shaft 3618 of FIGS. 36 and/or 37 . In some examples, the meansfor providing torque may include an electric motor, a stator, and/or arotor.

In some examples, the pump systems 3600, 3700 include means for mountingthe pump systems 3600, 3700. For example, the means for mounting may beimplemented by the mounting flanges 3632, 3732 and/or the motor housings3630, 3730 of FIGS. 36 and/or 37 . In some examples, the means formounting may include a flange, a housing, a plate, fasteners, and/orsupport structures.

In some examples, the pump systems 3600, 3700 include means for sealing.For example, the means for sealing may be implemented by the barrier can3616 of FIG. 36 and/or the piston seal 3710 of FIG. 37 . In someexamples, the means for sealing may include a barrier can, a shroud, apiston seal, a hermetic seal, a gasket, and/or a diaphragm.

In some examples, the pump systems 3600, 3700 include means for firstconnecting. For example, the means for first connecting may beimplemented by the magnetic coupling 3610 of FIG. 36 and/or the splinedinterface 3722 of FIG. 37 . In some examples, the means for firstconnecting may include a magnetic coupling, a mechanical coupling,fasteners (e.g., bolts, adhesives, interference fits, welds, etc.),and/or a splined interface.

In some examples, pump systems 3600, 3700 include means for coupling.For example, the means for coupling may be implemented by the magneticcoupling 3610 of FIG. 36 . In some examples, the means for coupling mayinclude a magnetic coupling and/or a mechanical coupling (e.g.,fasteners, adhesives, interference fits, etc.).

In some examples, the pump systems 3600, 3700 include means for secondconnecting. For example, the means for second connecting may beimplemented by the splined interface 3622 of FIG. 36 . In some examples,the means for second connecting may include a splined interface, amechanical coupling, a magnetic coupling, and/or a mechanical fastener.

In some examples, the pump systems 3600, 3700 include means forsupporting. For example, the means for supporting may be implemented bythe pump housings 3608, 3708, the motor housings 3630, 3730, the radialimpeller bearings 3606, 3706, and/or the radial motor bearings 3628,3728 of FIGS. 36 and/or 37 . In some examples, the means for supportingmay include additively manufactured housings, subtractive manufacturedhousings, rolling-element bearings, and/or foil bearings.

In some examples, the pump systems 3600, 3700 include means fortransferring heat. In some examples, the means for transferring mayinclude a cooling jacket (e.g., cooling jacket 416 of FIG. 4 , coolingjackets 514, 614, 714 of FIGS. 5-7 , etc.), cooling fins, cooling vents,and/or coolant flowlines.

In some examples, the pump systems 3600, 3700 include means forattaching. In some examples, the means for attaching may includemechanical fasteners (e.g., bolts, dowels, screws, etc.) and/or magneticcouplings. In some examples, the means for attaching include aconfiguration of a first housing (e.g., the pump housings 3608, 3708 ofFIGS. 36, 37 ) to be removable from a second housing (e.g., the motorhousings 3630, 3730 of FIGS. 36, 37 ).

In some examples, pump systems 3600, 3700 include means for separating.For example, the means for separating may be implemented by the oilseparator 3216 of FIGS. 32-35 . In some examples, the means forseparating may include an oil separator, a filter, an extractor, and/ora purifier.

Example axial flux motor driven pump systems for pressurizing fluid inclosed loop systems are disclosed herein. The example axial flux motordriven pump systems disclosed herein include an axial flux motor toprovide torque to a pump while reducing the axial length of the pumpsystem relative to example radial flux motor driven pump systems andmoving the center of gravity closer to a mounting flange. The exampleaxial flux motor driven pump systems disclosed herein thereby reduce themoment forces acting on the pump systems and/or the mounting flanges dueto weight, forced oscillations, and/or vibrations, which, in turn,reduces wear and/or damage to the pump systems. The example axial fluxmotor driven pump systems disclosed herein include pumps that aredesigned as line replaceable units, which include a pump housing that isremovable from the pump system without having to remove the entire pumpsystem from the mounting surface. The example axial flux motor drivenpump systems are, therefore, easier to maintain and/or repair thanradial flux motor driven pump systems.

From the foregoing, it will be appreciated that example systems,methods, apparatus, and articles of manufacture have been disclosed thatincrease a pressure and/or a flow rate at which a fluid pump can drive afluid (e.g., a heat transfer fluid such as a supercritical fluid (e.g.,sCO2, etc.)). Specifically, the example systems, methods, apparatus, andarticles of manufacture disclosed herein enable the impeller to bedriven with a greater angular velocity that, in turn, enables the fluidto reach higher pressures and/or flow rates. Furthermore, the examplesdisclosed herein enable the pumps and/or pump systems to operate withfewer components and/or smaller components that enable a cost of thepump or pump system to be minimized or otherwise reduced.

The foregoing examples of the pumps can be used with thermal transportsystems. Although each example pump or pump system disclosed above hascertain features, it should be understood that it is not necessary for aparticular feature of one example pump or pump system to be usedexclusively with that example. Instead, any of the features describedabove and/or depicted in the drawings can be combined with any of theexamples, in addition to or in substitution for any of the otherfeatures of the examples. Features of one example are not mutuallyexclusive to features of another example. Instead, the scope of thisdisclosure encompasses any combination of any of the features.

Further aspects of the present disclosure are provided by the subjectmatter of the following clauses:

Example methods, apparatus, systems, and articles of manufacture topressurize fluid in closed loop systems are disclosed herein. Furtherexamples and combinations thereof include the following:

Example 1 includes a pump system to pressurize a fluid within a closedloop transport bus, the pump system comprising an electric motorincluding a rotor shaft and a stator, a pump including an impellercoupled to an impeller shaft, a driver wheel attached to the rotorshaft, wherein the driver wheel is radially connected to a followerwheel, and a co-axial magnetic coupling to connect at least one of thefollower wheel to the impeller shaft or the driver wheel to the rotorshaft, wherein the co-axial magnetic coupling includes an outer hub, aninner hub, and a barrier can, the barrier can to hermetically seal aportion of the pump system from the fluid.

Example 2 includes the pump system of any preceding clause, wherein therotor shaft is to generate a first torque, the driver wheel is totransmit the first torque to the follower wheel, the follower wheel isto generate a second torque.

Example 3 includes the pump system of any preceding clause, wherein thedriver wheel has a first diameter, wherein the follower wheel has asecond diameter, and wherein the first diameter is greater than thesecond diameter.

Example 4 includes the pump system of any preceding clause, wherein thedriver wheel is a first gear, wherein the follower wheel is a secondgear, and wherein the first gear is radially connected to the secondgear via interlocking gear teeth.

Example 5 includes the pump system of any preceding clause, wherein thedriver wheel is a first pulley, wherein the follower wheel is a secondpulley, and wherein the first pulley is radially connected to the secondpulley via a drive belt.

Example 6 includes the pump system of any preceding clause, wherein thestator is inside of the rotor shaft, the rotor shaft is configured to bethe driver wheel to transmit a first torque to the follower wheel, thefollower wheel is to generate a second torque.

Example 7 includes the pump system of any preceding clause, wherein thepump system includes one or more additively manufactured housings toframe at least one of the stator, the rotor shaft, the impeller, theimpeller shaft, or the co-axial magnetic coupling, the one or moreadditively manufactured housings to support at least one or more radialbearings or one or more thrust bearings, the one or more additivelymanufactured housings to configure an impeller shaft axis and a rotorshaft axis to be parallel and to be on separate planes.

Example 8 includes the pump system of any preceding clause, wherein theone or more radial bearings include at least one of foil bearings,rolling element bearings, hydrostatic bearings, or hydrodynamicbearings, the one or more radial bearings to support one or more radialloads produced by at least one of the impeller shaft, the rotor shaft,the co-axial magnetic coupling, the driver wheel, or the follower wheel.

Example 9 includes the pump system of any preceding clause, wherein theone or more thrust bearings include at least one of foil bearings,rolling element bearings, hydrostatic bearings, or hydrodynamicbearings, the one or more thrust bearings to support one or more thrustloads produced by at least one of the impeller shaft, the rotor shaft,the co-axial magnetic coupling, the driver wheel, or the follower wheel.

Example 10 includes the pump system of any preceding clause, wherein theone or more additively manufactured housings include one or more coolingjackets to dissipate heat from the electric motor to at least one ofambient air or fluid coolant.

Example 11 includes a pump system to pressurize a fluid within a closedloop transport bus, the pump system comprising an electric motorincluding a rotor shaft and a stator, wherein the stator is to induce afirst angular velocity of the rotor shaft, a pump including an impellercoupled to an impeller shaft, wherein the impeller shaft is to rotate ata second angular velocity, and wherein the pump is to increase a kineticenergy of the fluid, a driver wheel fixed to the rotor shaft, whereinthe driver wheel is radially connected to a follower wheel, and aco-axial magnetic coupling to couple at least one of the follower wheelto the impeller shaft or the driver wheel to the rotor shaft, whereinthe co-axial magnetic coupling includes an outer hub, an inner hub, anda barrier can, the barrier can to hermetically seal a portion of thepump system from the fluid.

Example 12 includes the pump system of any preceding clause, wherein thedriver wheel is to transfer the first angular velocity to the followerwheel, the follower wheel to rotate at the second angular velocity.

Example 13 includes the pump system of any preceding clause, wherein thedriver wheel has a first diameter, wherein the follower wheel has asecond diameter, and wherein the first diameter is greater than thesecond diameter.

Example 14 includes the pump system of any preceding clause, wherein thedriver wheel is a first gear, wherein the follower wheel is a secondgear, and wherein the first gear is radially connected to the secondgear via interlocking gear teeth.

Example 15 includes the pump system of any preceding clause, wherein thedriver wheel is a first pulley, wherein the follower wheel is a secondpulley, and wherein the first pulley is radially connected to the secondpulley via a drive belt.

Example 16 includes the pump system of any preceding clause, wherein thestator is inside of the rotor shaft, wherein the rotor shaft includesone or more gear teeth protruding outward on the rotor shaft, the driverwheel to transfer the first angular velocity to the follower wheel, thefollower wheel to rotate at the second angular velocity.

Example 17 includes the pump system of any preceding clause, wherein thepump system includes one or more additively manufactured housings toframe at least one of the stator, the rotor shaft, the impeller, theimpeller shaft, or the co-axial magnetic coupling, the one or moreadditively manufactured housings to support at least one or more radialbearings or one or more thrust bearings, the one or more additivelymanufactured housings to configure an impeller shaft axis and a rotorshaft axis to be parallel and to be on separate planes.

Example 18 includes the pump system of any preceding clause, wherein theone or more radial bearings include at least one of foil bearings,rolling element bearings, hydrostatic bearings, or hydrodynamicbearings, the one or more radial bearings to support one or more radialloads produced by at least one of the impeller shaft, the rotor shaft,the co-axial magnetic coupling, the driver wheel, or the follower wheel.

Example 19 includes the pump system of any preceding clause, wherein theone or more thrust bearings include at least one of foil bearings,rolling element bearings, hydrostatic bearings, or hydrodynamicbearings, the one or more thrust bearings to support one or more thrustloads produced by at least one of the impeller shaft, the rotor shaft,the co-axial magnetic coupling, the driver wheel, or the follower wheel.

Example 20 includes the pump system of any preceding clause, wherein theone or more additively manufactured housings include a cooling jacket todissipate heat from the electric motor to at least one of ambient air orfluid coolant.

Example 21 includes a pump system to pressurize a fluid within a closedloop transport bus, the pump system comprising means for rotating adriver wheel, wherein the means for rotating is to exert a first torqueon the driver wheel, and wherein the means for rotating is to generate afirst angular velocity of the driver wheel based on the first torque,means for accelerating a flow rate of the fluid, wherein the means foraccelerating is to rotate an impeller shaft at a second angular velocitybased on a second torque, means for converting the first torque of thedriver wheel into the second torque of a follower wheel, wherein themeans for converting is to generate the second angular velocity of thefollower wheel based on the second torque, and means for connecting atleast one of the follower wheel to the impeller shaft or the driverwheel to a rotor shaft, wherein the means for connecting is tohermetically seal a portion of the pump system from the fluid.

Example 22 includes the pump system of any preceding clause, wherein themeans for connecting is to transfer at least one of the first torque orthe second torque from a first shaft to a second shaft.

Example 23 includes the pump system of any preceding clause, furtherincluding means for framing at least one of a stator, the rotor shaft,an impeller, the impeller shaft, or a co-axial magnetic coupling,wherein the means for framing is to support at least one or more radialbearings or one or more thrust bearings, and wherein the means forframing is to configure an impeller shaft axis and a rotor shaft axis inparallel and on separate planes.

Example 24 includes the pump system of any preceding clause, wherein themeans for framing is to transfer heat from an electric motor to at leastone of ambient air or fluid coolant.

Example 25 includes a pump system to pressurize a fluid within a closedloop transport bus, the pump system comprising a pump, including animpeller, an electric motor, including a rotor shaft connected to theimpeller, a first bearing to support the rotor shaft at a firstoperational speed range, the first bearing coupled to an inner race, asecond bearing to support the rotor shaft at a second operational speedrange, the rotor shaft coupled to an outer race, and one or more spragelements configured to engage the inner race with the outer race at thefirst operational speed range, and disengage the inner race from theouter race at the second operational speed range.

Example 26 includes the pump system of any preceding clause, wherein thefirst bearing is a rolling element bearing including at least one of anangular contact ball bearing, a hybrid ceramic bearing, a taper rollerbearing, a deep groove single ball bearing, a duplex ball bearing, or aspherical bearing.

Example 27 includes the pump system of any preceding clause, wherein thefirst bearing is to be lubricated by an oil lubricant, further includinga separator to separate the oil lubricant from the fluid, a portion ofthe oil lubricant to be mixed with the fluid.

Example 28 includes the pump system of any preceding clause, wherein thesecond bearing is a foil bearing.

Example 29 includes the pump system of any preceding clause, wherein, inresponse to the rotor shaft rotating in a first direction about a rotoraxis at the first operational speed range, the one or more spragelements rotate in a second direction about a sprag rotation axis, thesecond direction different than the first direction.

Example 30 includes the pump system of any preceding clause, wherein, inresponse to the rotor shaft rotating in a first direction about a rotoraxis at the second operational speed range, the one or more spragelements rotate in a second direction about a sprag rotation axis, thesecond direction same as the first direction.

Example 31 includes the pump system of any preceding clause, wherein theone or more sprag elements are configured to rotate in the seconddirection in response to a centrifugal force acting on a portion of theone or more sprag elements, the centrifugal force generated in responseto the pump system operating at the second operational speed range.

Example 32 includes the pump system of any preceding clause, wherein theone or more sprag elements include at least one of a solid lubricant oran oil mist lubricant, the solid lubricant including a silver coating.

Example 33 includes the pump system of any preceding clause, wherein thefirst operational speed range includes tangential velocities that areless than a foil bearing lift off speed.

Example 34 includes the pump system of any preceding clause, wherein thesecond operational speed range includes tangential velocities that aregreater than a foil bearing lift off speed.

Example 35 includes the pump system of any preceding clause, furtherincluding a thrust bearing to support a thrust load generated by therotor shaft, the thrust bearing including at least one of a thrust foilbearing or a thrust magnetic bearing.

Example 36 includes an integrated bearing system to dynamically supportshafts in a pump system, the pump system to pressurize a fluid within aclosed loop transport bus, the integrated bearing system comprising ashaft connected to an impeller of the pump system, a first bearing tosupport the shaft at a first operational speed range, the first bearingcoupled to an inner race, a second bearing to support the shaft at asecond fluid speed range, the shaft coupled to an outer race, and one ormore sprag elements configured to engage the inner race with the outerrace at the first operational speed range, and disengage the inner racefrom the outer race at the second operational speed range.

Example 37 includes the integrated bearing system of any precedingclause, wherein the first bearing is a rolling element bearing includingat least one of an angular contact ball bearing, a hybrid ceramicbearing, a taper roller bearing, a deep groove single ball bearing, aduplex ball bearing, or a spherical bearing.

Example 38 includes the integrated bearing system of any precedingclause, wherein the first bearing is to be lubricated by an oillubricant, further including a separator to separate the oil lubricantfrom the fluid, a portion of the oil lubricant to be mixed with thefluid.

Example 39 includes the integrated bearing system of any precedingclause, wherein the second bearing is a foil bearing.

Example 40 includes the integrated bearing system of any precedingclause, wherein, in response to the shaft rotating in a first directionabout a shaft axis at the first operational speed range, the one or moresprag elements rotate in a second direction about a sprag rotation axis,the second direction different than the first direction.

Example 41 includes the integrated bearing system of any precedingclause, wherein, in response to the shaft rotating in a first directionabout a rotor axis at the second operational speed range, the one ormore sprag elements rotate in a second direction about a sprag rotationaxis, the second direction same as the first direction.

Example 42 includes the integrated bearing system of any precedingclause, wherein the one or more sprag elements are configured to rotatein the second direction in response to a centrifugal force acting on aportion of the one or more sprag elements, the centrifugal forcegenerated in response to the pump system operating at the secondoperational speed range.

Example 43 includes the pump system of any preceding clause, wherein theone or more sprag elements include at least one of a solid lubricant oran oil mist lubricant, the solid lubricant including a silver coating.

Example 44 includes the pump system of any preceding clause, wherein thefirst operational speed range includes tangential velocities that areless than a foil bearing lift off speed.

Example 45 includes the pump system of any preceding clause, wherein thesecond operational speed range includes tangential velocities that aregreater than a foil bearing lift off speed.

Example 46 includes a pump system to pressurize a fluid within a closedloop supercritical transport bus, the pump system comprising means forincreasing kinetic energy of the fluid flowing through the pump system,means for providing torque to a rotor shaft of the pump system, meansfor first supporting the rotor shaft at a first operational speed range,means for second supporting the rotor shaft at a second operationalspeed range, and means for engaging an inner race with an outer race atthe first operational speed range.

Example 47 includes the pump system of any preceding clause, wherein themeans for engaging is to, in response to the rotor shaft rotating in afirst direction about a rotor axis at the second operational speedrange, disengage the inner race from the outer race based on acentrifugal force generated by the rotor shaft.

Example 48 includes the pump system of any preceding clause, wherein, inresponse to the rotor shaft rotating in a first direction about a rotoraxis at the second operational speed range, the means for engaging is torotate in a second direction about a sprag rotation axis, the seconddirection same as the first direction.

Example 49 includes the pump system of any preceding clause, furtherincluding means for separating one or more liquids from the fluid, theone or more liquids including oil.

Example 50 includes a shroud for a pump comprising an inner shellincluding a first non-metallic material, an outer shell including thefirst non-metallic material or a second non-metallic material, and ametal core shell positioned between the inner shell and the outer shell.

Example 51 includes the shroud of any preceding clause, wherein themetal core shell is electroformed.

Example 52 includes the shroud of any preceding clause, wherein at leastone of the inner shell or the outer shell is formed via thermalspraying.

Example 53 includes the shroud of any preceding clause, wherein theinner shell is formed via at least one of molding or casting.

Example 54 includes the shroud of any preceding clause, wherein thefirst non-metallic material and the second non-metallic material includeat least one of a ceramic, a polymer, or a composite.

Example 55 includes the shroud of any preceding clause, wherein theinner shell includes a first thickness, the outer shell includes thefirst thickness or a second thickness, and the metal core shell includesa third thickness greater than the first thickness and the secondthickness.

Example 56 includes the shroud of any preceding clause, wherein theinner shell includes ridges extending away from a cavity defined by theshroud, the ridges spaced apart along a circumference of the innershell.

Example 57 includes the shroud of any preceding clause, wherein an outersurface of the metal core shell is fully in contact with an innersurface of the outer shell.

Example 58 includes a canned motor pump comprising a first shaft, asecond shaft at least partially positioned around the first shaft, thesecond shaft magnetically engaged with the first shaft, and a shroudpositioned between the first shaft and the second shaft, the shroudincluding a metallic core layer, a first non-metallic layer positionedbetween the metallic core layer and the first shaft, and a secondnon-metallic layer positioned between the metallic core layer and thesecond shaft.

Example 59 includes the canned motor pump of any preceding clause,wherein the metallic core layer includes at least one of nickel orcobalt.

Example 60 includes the canned motor pump of any preceding clause,wherein the first non-metallic layer includes a first portion having afirst thickness and a second portion having a second thickness greaterthan the first thickness.

Example 61 includes the pump system of any preceding clause, wherein themetallic core layer includes a first portion having a first outerdiameter and a second portion having a second outer diameter.

Example 62 includes the canned motor pump of any preceding clause,wherein the first non-metallic layer and the second non-metallic layerinclude at least one of a ceramic material, a composite material, or apolymer material.

Example 63 includes the canned motor pump of any preceding clause,wherein the first non-metallic layer and the second non-metallic layerinclude at least one of alumina, zirconia, or silicon.

Example 64 includes the canned motor pump of any preceding clause,wherein the shroud includes a flange, further including a retainer ringto secure the flange against a housing of the canned motor pump.

Example 65 includes a magnetically driven pump comprising means forhousing a fluid, means for compressing the fluid, and means for sealingthe means for housing, the means for sealing including first means forinsulating to define an inner surface of the means for sealing, secondmeans for insulating to define an outer surface of the means forsealing, and means for supporting the first means for insulating and thesecond means for insulating, the means for supporting to fill an areadefined between the first means for insulating and the second means forinsulating.

Example 66 includes the magnetically driven pump of any precedingclause, wherein the means for supporting is electroformed over the firstmeans for insulating.

Example 67 includes the magnetically driven pump of any precedingclause, wherein at least one of the first means for insulating or thesecond means for insulating is formed via thermal spraying.

Example 68 includes the magnetically driven pump of any precedingclause, wherein at least one of the first means for insulating or themeans for supporting includes means for stiffening.

Example 69 includes the magnetically driven pump of any precedingclause, wherein the fluid is a first means for dissipating heat incontact with the first means for insulating, further including a secondmeans for dissipating heat in contact with the second means forinsulating

Example 70 includes a method of manufacturing a shroud for a cannedmotor pump comprising forming an inner shell, electroforming a coreshell on an outer surface of the inner shell, and forming an outer shellon an outer surface of the core shell.

Example 71 includes a method of manufacturing a shroud for a cannedmotor pump comprising forming an inner shell, forming an outer shell,and electroforming a core shell on an outer surface of the inner shellor on an inner surface of the outer shell.

Example 72 includes the method of any preceding clause, wherein formingthe inner shell includes at least one of molding, casting, or thermalspraying the inner shell.

Example 73 includes the method of any preceding clause, wherein formingthe inner shell includes forming ribs protruding from an outer surfaceof the inner shell.

Example 74 includes the method of any preceding clause, wherein formingthe outer shell includes thermal spraying the outer shell on the outersurface of the core shell.

Example 75 includes the method of any preceding clause, wherein at leastone of forming the inner shell or forming the outer shell includesmachining or grinding an inner surface of the inner shell or an outersurface of the outer shell.

Example 76 includes the canned motor pump of any preceding clause,wherein the first non-metallic layer includes a first thickness and asecond thickness greater than the first thickness, the first thicknessand the second thickness alternating in a circumferential directiondefined by the first non-metallic layer.

Example 77 includes the canned motor pump of any preceding clause,further including an O-ring positioned between the barrier can and theretainer ring

Example 78 includes the canned motor pump of any preceding clause,wherein the retainer ring is coupled to the housing via bolts.

Example 79 includes the canned motor pump of any preceding clause,wherein the retainer ring includes a first portion having a firstdiameter and a second portion having a second diameter smaller than thefirst diameter, the flange including a third diameter between the firstdiameter and the second diameter.

Example 80 includes the canned motor pump of any preceding clause,wherein the first portion of the retainer ring is to interface with thehousing, and the second portion of the retainer ring is separated fromthe housing by a distance corresponding to a thickness of the flangesuch that the second portion of the retainer ring presses the flangeagainst the housing when the retainer ring is coupled to the housing.

Example 81 includes the canned motor pump of any preceding clause,wherein the first non-metallic layer is in contact with a first fluidand the second non-metallic layer is in contact with a second fluiddifferent from the first fluid, wherein the barrier can is to exchangethermal energy with at least one of the first fluid or the second fluid.

Example 82 includes the magnetically driven pump of any precedingclause, wherein the first means for insulating includescircumferentially spaced ribs extending away from a cavity defined bythe means for sealing.

Example 83 includes the shroud of any preceding clause, wherein themetal core shell includes a thickness as small as 0.005 inches.

Example 84 includes the shroud of any preceding clause, wherein an innersurface of the metal core shell is fully in contact with an outersurface of the inner shell.

Example 85 includes a shroud for a fluid pump comprising an inner shellincluding a thermoplastic composite or a metal, and an outer shellincluding a composite material.

Example 86 includes the shroud of any preceding clause, wherein theinner shell includes a nickel-based alloy.

Example 87 includes the shroud of any preceding clause, wherein thethermoplastic composite is a polyamide-imide

Example 88 includes the shroud of any preceding clause, wherein thethermoplastic composite is a polyetheretherketone.

Example 89 includes the shroud of any preceding clause, wherein theinner shell is formed via machining rods of the thermoplastic composite.

Example 90 includes the shroud of any preceding clause, wherein theouter shell is formed in layers on the inner shell.

Example 91 includes the shroud of any preceding clause, wherein theinner shell is electroformed on an inner surface of the outer shell.

Example 92 includes the shroud of any preceding clause, wherein thecomposite material includes an epoxy resin.

Example 93 includes the shroud of any preceding clause, wherein thecomposite material includes at least one of carbon fibers or graphitefibers.

Example 94 includes the shroud of any preceding clause, wherein at leastone of the carbon fibers or the graphite fibers are positioned in morethan one orientation.

Example 95 includes the shroud of any preceding clause, wherein thecomposite material includes fibers positioned in a first orientation, asecond orientation different from the first orientation, a thirdorientation different from the first orientation and the secondorientation, and a fourth orientation different from the firstorientation, the second orientation, and the third orientation.

Example 96 includes the shroud of any preceding clause, wherein thefirst orientation is substantially orthogonal to the second orientation.

Example 97 includes the shroud of any preceding clause, wherein thethird orientation is substantially orthogonal to the fourth orientation.

Example 98 includes the shroud of any preceding clause, wherein theouter shell includes a thickness between 25 mils and 150 mils.

Example 99 includes a magnetically driven pump comprising a first shaft,a second shaft at least partially positioned around the first shaft, thesecond shaft magnetically engaged with the first shaft, and a shroudpositioned between the first shaft and the second shaft, the shroudincluding a composite shell, and a liner positioned along an innersurface of the composite shell, the liner including a thermoplastic or ametal.

Example 100 includes the magnetically driven pump of any precedingclause, wherein the composite shell includes pores.

Example 101 includes the magnetically driven pump of any precedingclause, wherein the composite shell includes fibers and an epoxy resin.

Example 102 includes the magnetically driven pump of any precedingclause, wherein the fibers are positioned in at least three distinctorientations.

Example 103 includes the magnetically driven pump of any precedingclause, wherein the fibers include at least one of carbon or graphite.

Example 104 includes the magnetically driven pump of any precedingclause, wherein a ratio of eddy current loss caused by the shroud to athickness of the liner is less than 0.06.

Example 105 includes the magnetically driven pump of any precedingclause, wherein the liner includes a nickel-chromium based alloy.

Example 106 includes a shroud for a canned motor pump, the shroudcomprising a composite shell including first fibers in a firstorientation and second fibers in a second orientation, the firstorientation substantially orthogonal to the second orientation, and aninner shell including a thermoplastic or a metal.

Example 107 includes the shroud of any preceding clause, wherein thecomposite shell includes third fibers in a third orientation and fourthfibers in a fourth orientation, the third orientation substantiallyorthogonal to the fourth orientation.

Example 108 includes a method for forming a shroud for a magneticallydriven pump, the method comprising forming a shell, machining an innersurface of the shell, and forming a liner along the inner surface of theshell.

Example 109 includes the method of any preceding clause, wherein formingthe shell includes molding the shell.

Example 110 includes the method of any preceding clause, wherein formingthe shell includes orienting fibers in more than one orientation.

Example 111 includes the method of any preceding clause, wherein formingthe shell includes binding the fibers via an epoxy resin.

Example 112 includes the method of any preceding clause, wherein formingthe liner includes electroforming the liner on the inner surface of theshell.

Example 113 includes the method of any preceding clause, wherein formingthe liner includes injection molding the liner on the inner surface ofthe shell.

Example 114 includes a method for forming a shroud for a magneticallydriven pump, the method comprising forming an inner shell, and layeringan outer shell on an outer surface of the inner shell.

Example 115 includes the method of any preceding clause, wherein theinner shell is formed via machining rods of thermoplastic.

Example 116 includes the method of any preceding clause, whereinlayering the outer shell includes layering a first layer of the outershell on the outer surface of the inner shell, and layering a secondlayer of the outer shell on the first layer.

Example 117 includes the method of any preceding clause, furtherincluding thermosetting the first layer in advance of layering thesecond layer on the first layer.

Example 118 includes the method of any preceding clause, furtherincluding orienting fibers in at least one of the first layer or thesecond layer.

Example 119 includes the method of any preceding clause, furtherincluding orienting fibers in more than one orientation in at least oneof the first layer or the second layer.

Example 119 includes the method of any preceding clause, whereinorienting the fibers includes positioning a first set of fibers in afirst orientation, and positioning a second set of fibers in a secondorientation substantially orthogonal to the first orientation.

Example 120 includes the method of any preceding clause, whereinorienting the fibers further includes positioning a third set of fibersin a third orientation different from the first orientation and thesecond orientation, and positioning a fourth set of fibers in a fourthorientation substantially orthogonal to the third orientation.

Example 121 includes the method of any preceding clause, wherein theinner shell is formed via electroforming.

Example 122 includes the shroud of any preceding clause, wherein theinner shell includes a thickness as small as 2 mils.

Example 123 includes the magnetically driven pump of any precedingclause, wherein the shroud is to withstand a pressure of 6400 pounds persquare inch absolute.

Example 124 includes the magnetically driven pump any preceding clausewherein the fibers are positioned in at least three distinctorientations.

Example 125 includes a pump system to pressurize a supercritical fluidwithin a closed loop thermal transport bus, the pump system comprising apump housing, a duct fluidly coupled to the pump housing, a firstportion of the duct to include a mixture of an oil and the supercriticalfluid, a second portion of the duct to include the supercritical fluid,and a separator positioned in a third portion of the duct between thefirst portion of the duct and the second portion of the duct, theseparator to separate the oil in the mixture from the supercriticalfluid.

Example 126 includes the pump system of any preceding clause, whereinthe separator includes a rotatable shaft and vanes extending from therotatable shaft.

Example 127 includes the pump system of any preceding clause, whereinthe separator includes a conical swirler, the conical swirler includingopen axial ends and holes in a surface between the open axial ends.

Example 128 includes the pump system of any preceding clause, whereinthe separator includes a rotatable shaft including vanes, and a casingpositioned around the rotatable shaft, the casing including holes facingthe rotatable shaft.

Example 129 includes the pump system of any preceding clause, whereinthe casing is stationary within the duct.

Example 130 includes the pump system of any preceding clause, whereinthe rotatable shaft rotates in a first direction and the casing rotatesin a second direction opposite the first direction.

Example 131 includes the pump system of any preceding clause, whereinthe separator includes a swirler and a filter positioned in series inthe third portion of the duct.

Example 132 includes the pump system of example 1, wherein the duct isfluidly coupled to a first portion of the pump housing and a secondportion of the pump housing.

Example 133 includes the pump system of any preceding clause, furtherincluding a rotatable shaft disposed in the pump housing, a motorcoupled to the rotatable shaft, and an impeller coupled to an end of therotatable shaft.

Example 134 includes the pump system of any preceding clause, whereinthe rotatable shaft is mounted in the pump housing via rolling elementbearings, wherein the rolling element bearings are lubricated with theoil.

Example 135 includes the pump system of any preceding clause, whereinthe end of the rotatable shaft is a first end, wherein the rotatableshaft includes a second end opposite the first end, a first portion ofthe rotatable shaft disposed between the first end and the motor, asecond portion of the rotatable shaft disposed between the second endand the motor, further including a first bearing coupled to the firstportion of the rotatable shaft, the first bearing including a firststiffness, and a second bearing coupled to the second portion of therotatable shaft, the second bearing including a second stiffness greaterthan the first stiffness.

Example 136 includes the pump system of any preceding clause, furtherincluding a first rotatable shaft disposed in the pump housing, a motorcoupled to the first rotatable shaft, a second rotatable shaft disposedin the pump housing, a gearbox to rotatably couple the first rotatableshaft and the second rotatable shaft, wherein the gearbox is lubricatedwith the oil, and an impeller coupled to an end of the second rotatableshaft.

Example 137 includes a pump system to pressurize a supercritical fluidwithin a closed loop thermal transport bus, the pump system comprising apump housing, a duct fluidly coupled to the pump housing to transportthe supercritical fluid and an oil, and a separator including an oilabsorbent material positioned in the duct to separate the oil from thesupercritical fluid.

Example 138 includes the pump system of any preceding clause, whereinthe oil absorbent material includes at least one of a polymer or apowder.

Example 139 includes the pump system of any preceding clause, whereinthe separator includes baffles.

Example 140 includes the pump system of any preceding clause, whereinthe baffles are formed via sheet metals or additive manufacturing.

Example 141 includes the pump system of any preceding clause, whereinthe separator includes a first conduit fluidly coupled to a secondconduit below the first conduit, the second conduit including the oilabsorbent material.

Example 142 includes the pump system of any preceding clause, whereinthe oil is mixed with an additive to increase a viscosity of the oil.

Example 143 includes a pump system to pressurize a supercritical fluidwithin a closed loop thermal transport bus, the pump system comprisingmeans for compressing fluid, wherein the fluid includes a supercriticalfluid and an oil, means for housing the means for compressing fluid,means for transporting the fluid coupled to the means for housing, andmeans for separating the supercritical fluid and the oil positioned inthe means for transporting.

Example 144 includes the pump system of any preceding clause, furtherincluding means for rotating the means for compressing fluid, and meansfor increasing an angular velocity of the means for compressing fluidrelative to the means for rotating.

Example 145 includes the pump system of any preceding clause, furtherincluding an eductor in the first portion of the duct.

Example 146 includes the pump system of any preceding clause, whereinthe vanes are helical vanes.

Example 147 includes the pump system of any preceding clause, whereinthe first portion of the duct is fluidly coupled to the first portion ofthe pump housing and the second portion of the pump housing.

Example 148 includes the pump system of any preceding clause, whereinthe first portion of the duct is fluidly coupled to the first portion ofthe pump housing, and wherein the second portion of the duct is fluidlycoupled to the second portion of the pump housing.

Example 149 includes the pump system of any preceding clause, whereinthe end of the rotatable shaft is a first end, wherein the rotatableshaft includes a second end opposite the first end, a first portion ofthe rotatable shaft disposed between the first end and the motor, asecond portion of the rotatable shaft disposed between the second endand the motor, further including a squirrel cage coupled to the firstportion of the rotatable shaft, and a damper coupled to the secondportion of the rotatable shaft.

Example 150 includes the pump system of any preceding clause, whereinthe oil absorbent material includes at least one of polyurethane,polypropylene, polyethylene, cross-linked polymers, talc, aluminumstarch, rice starch, or silica.

Example 151 includes the pump system of any preceding clause, furtherincluding means for rotating the means for compressing, wherein themeans for rotating is separated from the means for compressing by afirst distance, first means for supporting the means for rotating, thefirst means for supporting including a first stiffness, wherein thefirst means for supporting is separated from the means for compressingby a second distance greater than the first distance, and second meansfor supporting the means for rotating, the second means for supportingincluding a second stiffness different from the first stiffness, whereinthe second means for supporting is separated from the means forcompressing by a third distance less than the first distance.

Example 152 includes a pump system comprising a pump housing a rotatableshaft disposed in the pump housing, a motor coupled to the rotatableshaft in the pump housing, an impeller coupled to an end of therotatable shaft, oil lubricated bearings to mount the rotatable shaft, aduct fluidly coupled to the pump housing, and a separator positioned inthe duct to separate oil from other fluid transported via the duct.

Example 153 includes a pump system to pressurize a fluid within a closedloop fluid transport bus, the pump system comprising an impeller coupledto an impeller shaft, an axial flux electric motor including rotors, arotor shaft connected to the rotors, wherein the rotor shaft is coupledto the impeller shaft, a seal to inhibit contact between the fluid andthe axial flux electric motor, a first housing to frame the impellershaft, and a second housing to frame the axial flux electric motor,wherein the second housing is separate from the first housing.

Example 154 includes the pump system of any preceding clause, whereinthe rotor shaft is connected to the impeller shaft via a splinedinterference.

Example 155 includes the pump system of any preceding clause, whereinthe seal is a piston seal ring mounted on the second housing, whereinthe impeller shaft is configured to fit within the piston seal ring.

Example 156 includes the pump system of any preceding clause, whereinthe impeller shaft is a first shaft, wherein a second shaft is coupledto the first shaft, and wherein the second shaft is connected to therotor shaft via a splined interference.

Example 157 includes the pump system of any preceding clause, whereinthe first shaft is coupled to the second shaft via a co-axial magneticcoupling, wherein the co-axial magnetic coupling includes an outer huband an inner hub, wherein the outer hub and the inner hub include one ormore permanent magnets.

Example 158 includes the pump system of any preceding clause, whereinthe seal is a barrier can that is mounted between the inner hub and theouter hub of the co-axial magnetic coupling, the barrier can includingat least one of a metallic material and a non-metallic material.

Example 159 includes the pump system of any preceding clause, furtherincluding one or more rolling element bearings to support a radial loadand a thrust load generated by the rotor shaft in the second housing,wherein the one or more rolling element bearings are lubricated via atleast one of an oil lubricant or a solid lubricant.

Example 160 includes the pump system of any preceding clause, whereinthe rolling element bearings are lubricated via the oil lubricant,further including a separator to separate the oil lubricant from thefluid, a portion of the oil lubricant to be mixed with the fluid.

Example 161 includes the pump system of any preceding clause, furtherincluding at least one or more rolling element bearings or one or moregas foil bearings to support a radial load and a thrust load generatedby the impeller shaft in the first housing, wherein the one or morerolling element bearings are lubricated via at least one of an oillubricant or a solid lubricant.

Example 162 includes the pump system of any preceding clause, whereinheat produced by the stator is transferred to at least one of oil orwater.

Example 163 includes a pump system to pressurize a fluid within a closedloop fluid transport bus, the pump system comprising means forincreasing kinetic energy of the fluid flowing through the pump system,means for providing torque to a rotor shaft of the pump system, meansfor mounting the pump system, wherein the means for mounting is to framean axial flux motor, wherein the means for mounting is to frame at leastone of an impeller, an impeller shaft, or a co-axial magnetic couplingseparate from the axial flux motor, and means for sealing the fluid fromcontacting the axial flux motor.

Example 164 includes the pump system of any preceding clause, furtherincluding means for first connecting the impeller shaft and the rotorshaft.

Example 165 includes the pump system of any preceding clause, whereinthe impeller shaft is a first shaft, further including means forcoupling the first shaft to a second shaft.

Example 166 includes the pump system of any preceding clause, furtherincluding means for second connecting the second shaft and the rotorshaft.

Example 167 includes the pump system of any preceding clause, furtherincluding means for supporting at least one of a radial load or a thrustload generated by at least one of the rotor shaft, the impeller shaft,or the co-axial magnetic coupling.

Example 168 includes the pump system of any preceding clause, furtherincluding means for transferring heat from the axial flux motor to atleast one of oil, water, or ambient air.

Example 169 includes the pump system of any preceding clause, furtherincluding means for attaching a first housing to a second housing,wherein the means for attaching is to configure the first housing to beremovable from the second housing.

Example 170 includes the pump system of any preceding clause, furtherincluding means for separating one or more liquids from the fluid, theone or more liquids including oil.

Example 171 includes a pump system to pressurize a fluid within a closedloop fluid transport bus, the pump system comprising an impeller coupledto an impeller shaft, an axial flux electric motor including rotors, arotor shaft connected to the rotors, wherein the rotor shaft is coupledto the impeller shaft, a seal to inhibit contact between the fluid andthe axial flux electric motor, a first housing to frame the impellershaft, and a second housing to frame the axial flux electric motor,wherein the second housing is separate from the first housing.

Example 172 includes the pump system of any preceding clause, whereinthe second housing includes a mounting flange to mount the pump systemto a mounting surface.

Example 173 includes the pump system of any preceding clause, furtherincluding a first line replaceable unit fixed to the second housing, thefirst line replaceable unit including at least one of the impeller, theimpeller shaft, the first housing, a co-axial magnetic coupling, and asecond shaft, wherein the second shaft is coupled to the impeller shaftvia the co-axial magnetic coupling, wherein the second housing is asecond line replaceable unit, the second line replaceable unit includingat least one of the axial flux electric motor or the rotor shaft, andwherein the first line replaceable unit is configured to be removablefrom the second line replaceable unit.

The following claims are hereby incorporated into this DetailedDescription by this reference. Although certain example systems,methods, apparatus, and articles of manufacture have been disclosedherein, the scope of coverage of this patent is not limited thereto. Onthe contrary, this patent covers all systems, methods, apparatus, andarticles of manufacture fairly falling within the scope of the claims ofthis patent.

What is claimed is:
 1. A shroud for a pump comprising: an inner shellincluding a first non-metallic material; an outer shell including thefirst non-metallic material or a second non-metallic material; and ametal core shell positioned between the inner shell and the outer shell.2. The shroud of claim 1, wherein the metal core shell is electroformed.3. The shroud of claim 1, wherein at least one of the inner shell or theouter shell is formed via thermal spraying.
 4. The shroud of claim 1,wherein the inner shell is formed via at least one of molding orcasting.
 5. The shroud of claim 1, wherein the first non-metallicmaterial and the second non-metallic material include at least one of aceramic, a polymer, or a composite.
 6. The shroud of claim 1, whereinthe inner shell includes a first thickness, the outer shell includes thefirst thickness or a second thickness, and the metal core shell includesa third thickness greater than the first thickness and the secondthickness.
 7. The shroud of claim 1, wherein the inner shell includesridges extending away from a cavity defined by the shroud, the ridgesspaced apart along a circumference of the inner shell.
 8. The shroud ofclaim 1, wherein an outer surface of the metal core shell is fully incontact with an inner surface of the outer shell.
 9. A canned motor pumpcomprising: a first shaft; a second shaft at least partially positionedaround the first shaft, the second shaft magnetically engaged with thefirst shaft; and a shroud positioned between the first shaft and thesecond shaft, the shroud including: a metallic core layer; a firstnon-metallic layer positioned between the metallic core layer and thefirst shaft; and a second non-metallic layer positioned between themetallic core layer and the second shaft.
 10. The canned motor pump ofclaim 9, wherein the metallic core layer includes at least one of nickelor cobalt.
 11. The canned motor pump of claim 9, wherein the firstnon-metallic layer includes a first portion having a first thickness anda second portion having a second thickness greater than the firstthickness.
 12. The canned motor pump of claim 9, wherein the metalliccore layer includes a first portion having a first outer diameter and asecond portion having a second outer diameter.
 13. The canned motor pumpof claim 9, wherein the first non-metallic layer and the secondnon-metallic layer include at least one of a ceramic material, acomposite material, or a polymer material.
 14. The canned motor pump ofclaim 9, wherein the first non-metallic layer and the secondnon-metallic layer include at least one of alumina, zirconia, orsilicon.
 15. The canned motor pump of claim 9, wherein the shroudincludes a flange, further including a retainer ring to secure theflange against a housing of the canned motor pump.
 16. A magneticallydriven pump comprising: means for housing a fluid; means for compressingthe fluid; and means for sealing the means for housing, the means forsealing including: first means for insulating to define an inner surfaceof the means for sealing; second means for insulating to define an outersurface of the means for sealing; and means for supporting the firstmeans for insulating and the second means for insulating, the means forsupporting to fill an area defined between the first means forinsulating and the second means for insulating.
 17. The magneticallydriven pump of claim 16, wherein the means for supporting iselectroformed over the first means for insulating.
 18. The magneticallydriven pump of claim 16, wherein at least one of the first means forinsulating or the second means for insulating is formed via thermalspraying.
 19. The magnetically driven pump of claim 16, wherein at leastone of the first means for insulating or the means for supportingincludes means for stiffening.
 20. The magnetically driven pump of claim16, wherein the fluid is a first means for dissipating heat in contactwith the first means for insulating, further including a second meansfor dissipating heat in contact with the second means for insulating.